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HomeProPlas Intercept® ESd Moisture Barrier Film
ProPlas Intercept® ESd Moisture Barrier Film
OVERVIEW
ProPlas Intercept® is the first ESd, Moisture Barrier Film capable of meeting Clean Room Requirements and other Environmental Protocal. This 'State of the Art' technology was designed for the protection of static and corrosion sensitive materials. Commonly used for ESd & moisture resistant gaylord liners for shipping, Static Intercept was developed by Lucent Technologies Bell Labs to solve the problems that electronics industry was experiencing with static and corrosion damage. By developing the Intercept Technology, they found a way to solve both corrosion and static problems with a single product, a feat no other single product can currently do. The dual functionality is what makes the technology so unique and revolutionary.

ProPlas Intercept® Packaging provides the following performance charactertistics:
  • Static Protection
  • Humidity Independence
  • Resistance Characteristics
  • Clean Room Uses
  • Stability
  • Corrosion Protection
  • Environmental Issues & Approvals

    Static Protection
    Basis of Technology
    The Static Intercept Technology is based on the covalent bonding of semi-conductors into the polymer matrix. During the compounding stage the raw materials are reacted together to form a homogeneous substance with all of the components permanently bonded into the polymer structure. Since it is a homogeneous structure it can go directly into the normal Polyethylene recycle stream. Due to this, Static Intercept meets the stringent German packaging material requirements, unlike some current ESD packaging, which cannot meet these standards.These characteristics allow Intercept to be combined with most of the polymers in current use such as (but not limited to) polyolifins, styrenes, and, polycarbonates. Unlike conductive carbon particles the use of semiconductors alows the doping of the polymer to follow a linear relationship with surface resistance. This alows the products to enjoy a permanent controlled static disapative characteristic. Through the use of chemical bonding corrosive gas neutralizing materials are distributed in the polymer chains. These materials provide total corrosion protection from atmospheric corrosive gases from damaging electrically conductive surfaces of the materials packaged in all Intercept products.

    Humidity Independence
    Static Intercept is humidity independent and does not use volatile chemicals, which coat products. ESD materials that function with the use volatile chemical antistats have unpredictable life times and depend on moisture in the air to form a water layer on the surface of the protective bag or tray. The static electric charge travels on this water layer. The need for a water layer causes the humidity dependence of the amine or amide technology. Materials using these volatile chemicals become insulative at Relative Humidity (RH) levels under 10 to 20%. Static Intercept's use of semi-conductor technology creates products that do not rely on any moisture to function. Static electric charges travel through a Static Intercept semi-conductor circuit, instead of through water.

    Resistance Characteristics
    Static Intercept can be produced in the range of 104 to 1010 Ohms/Square. Carbon loaded systems can only be produced in the range of 101 to 105, whereas volatile anti-stats are in the range of 1010 to 1012. Only Static Intercept spans the large Surface Resistivity range.

    Clean Room Uses
    Static Intercept is inherently clean. Static Intercept products have passed the strict qualifications of Bell Labs that allows them, with no pre-cleaning, to be used inside their clean rooms. The same is not true for Carbon based systems since they can be extremely dirty as well as have the potential to slough conductive carbon particles that can fall on sensitive devices causing shorts. Also, antistat based products have chemicals that will evaporate and can coat sensitive products with a layer of organic oil.

    Stability
    Static Intercept is not water soluble. Chemical coatings and internally loaded antistats are water soluble and are easily removed from the surface of the protective package. Chemical antistats have difficulty passing the 24 hour water bath test, but not Static Intercept that passes easily. Static Intercept is not affected by heat or cold. Chemical antistats are volatile chemicals and heat accelerates their evaporation. Products using chemical antistats, stored in hot conditions, can deplete their volatile chemicals in a short period of time. Static Intercept is a solid state and non volatile system that is unaffected by heat, cold, or time. Static Intercept passes both NASA and Raytheon outgassing specifications. Volatile chemical antistats by their very nature emits organic oils. Static Intercept uses only solid state components, so there are no volatile chemicals to outgas. Static Intercept combines all of the critical criteria (clean, RH independent, full static dissipative range, permanent, meeting German standards, unaffected by water or temperature extremes, and non-outgassing) for protecting sensitive parts.

    Corrosion Protection
    The most revolutionary characteristic of Static Intercept is that the technology combines these static properties with corrosion protection. Corrosion protection of up to 15 to 20 years is provided for non-ferrous metals (Silver, Copper, and their alloys such as brass and bronze). Ferrous metals enjoy over 100 times the corrosion protection of unprotected parts. The key to the corrosion protection is that the constituents of Static Intercept react with and permanently neutralize atmospheric corrosive gases as well as interrupt the electric current flow of galvanic corrosion. Non-ferrous metals corrode by contact with corrosive gases. These gases (COS, H2S, HCl, and SO2) are formed from burning fossil fuels and wood, from decaying vegetation, and from ocean surfaces. These gases are present in the environment around us. An audit at one semi-conductor manufacturing facility showed that there were concentrations of dangerous corrosive gases within the clean room facility. Ferrous metals corrode, or rust, by reaction with corrosive gases as well as by galvanic corrosion. Static Intercept acts as a sacrificial anode, similar to placing a piece of Zinc into a water heater to keep it from corroding. Static Intercept interrupts the galvanic current and sacrifices itself. Only Static Intercept combines protection for ferrous and non-ferrous metals. Bell Labs concluded that corrosion damage, and not just ESD, can cause latent defects. When electronic leads and traces corrode, they form insulative metal salts or oxides. These insulative metal oxides reduce the mass of the conductor that decreases the amount of electron flow that can be carried by that trace or lead. As the circuit approaches its rated current, the electron flow across the now narrower lead or trace can generate excessive amounts of damaging heat. This overheats the part, resulting in what looks like an ESD event, but in reality was corrosion induced. Careful SEM analysis of failed parts can verify this corrosion damage. Bell Labs found that Copper Bus bars, which are processed and cleaned at an outside company and shipped to Lucent, reach an unacceptably high junction resistance within 7 days of manufacture, due to surface corrosion. All bars have to be hand cleaned and buffed prior to being assembled into their final application. By using Static Intercept this problem was eliminated. Whether a part is moving inside or outside of the manufacturing facility, it is being attacked by corrosive gases. Using Static Intercept keeps these corrosive gases away from the sensitive parts. Catastrophic corrosion damage scenarios occur when sensitive parts are placed into storage or when they are transported across the country or ocean. Corrosive gases are present everywhere and can easily invade a product and begin to degrade it. Shipping across or storing near the ocean is extremely dangerous to corrosion sensitive parts because the ocean environment is so highly corrosive due to the abundance of HCl and COS gases. These gases easily pass through normal plastics and containers and attack sensitive components. By using Static Intercept the gases are kept away from these sensitive parts. Static Intercept contains a torturous path for corrosive gases to follow as they try to penetrate the bag, tote, or cushioning material wrap. It is statistically improbable that a corrosive gas could migrate through the plastic without quickly contacting an active corrosion protection component. Once the corrosive gas contacts an active component a chemical reaction occurs which permanently neutralizes the gas. Unlike charcoal paper that only traps corrosive gases (charcoal paper will release these gases in a highly concentrated form if the temperature increases) Static Intercept reacts with the corrosive gases in an irreversible chemical reaction. A chemical reaction that cannot adversely affect the part being protected. Under normal conditions, no corrosive gas will pass through the protective Static Intercept plastic. In addition, the air inside of a Static Intercept bag, tote, or cushioning material wrap is cleansed. Corrosive gases trapped inside the package see almost 3 times the affinity for a corrosion reaction to take place on the surface of the bag versus on the surface of the part being protected. Because of this characteristic, the gases will preferentially corrode the bag, instead of the part. This scavenging nature of the Static Intercept plastic is another reason why parts remain safely protected inside a loosely closed bag or a cushion material wrap.

    Environmental Issues
    Static Intercept can be easily recycled in the standard Polyethylene recycle stream. However, if the plastic is thrown away, it will have a substantially reduced landfill time. Typical biodegradable plastics use up to 15% corn starch additive. When these so called "Green" bags are disposed of, the corn starch filler in the bag is attacked by microbes that consume the starch making the bag fall apart, or producing what is commonly referred to as polymer dust. An important note is that the microbes that eat the corn starch need oxygen to survive. Landfills are anaerobic, so there is no oxygen present. Static Intercept does not need an aerobic environment to break down. Extremely high levels of corrosive gases are present in landfills. These gases react with and completely overwhelm the Static Intercept product. The product is forced to completely react with the gases, weakening the chemical bonds previously formed. This causes the bag to literally fall apart and become polymer dust. Using Static Intercept helps protect our fragile environment by providing shortened landfill times. Static Intercept is a unique technology. Materials made with the Intercept technology effectively protect static sensitive parts from the devastating effects of ESD events as well as safely protecting parts from harmful corrosive gases, all within an environmentally friendly framework.
  • FEATURES AND BENEFITS
    ProPlas Intercept® ESd Moisture Barrier Film for Packaging - Bagging Films provide: Static Protection, Humidity Independence, Resistance Characteristics, Clean Room Uses, Stability, Corrosion Protection, addresses Environmental Issues & Approvals.
       (STATIC INTERCEPT - PROPLAS) ProPlas Intercept® ESd Moisture Barrier Film


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