Abstract: An electrical component includes a conductive substrate, a tin layer formed on the substrate, and a barrier coating formed on the tin layer to impede tin whisker growth. The barrier coating includes a polymer matrix, and abrasive particles that are dispersed about the matrix.

Abstract: An electrical component includes a conductive substrate, a tin layer formed on the substrate, and a conformal coating formed on the tin layer to impede tin whisker growth. The conformal coating includes a polymer matrix, and particles that are dispersed about the matrix. The particles are either significantly harder than the polymer matrix, or are significantly softer than the polymer matrix.

Abstract: An electrical component includes a conductive substrate, a tin layer formed on the substrate, and a multi-phase coating formed on the tin layer to impede tin whisker growth. The multi-phase coating comprises a polymer matrix having pores dispersed therethrough, with the pores constituting at least 30% by volume of the coating. To form the multi-phase coating, the tin plating or finish is covered with a coating comprising a polymer matrix having a second material mixed therein. The second material is subsequently removed from the polymer matrix to produce a coating having pores in the matrix where the second material was disposed before being removed.

Abstract: An electrical component includes a conductive substrate, a tin layer formed on the substrate, and a conformal coating formed on the tin layer to impede tin whisker growth. The conformal coating comprises a polymer matrix having gas-filled voids dispersed therethrough. In a method for impeding tin whisker growth from a tin plating or finish formed over an electrical component, a gas is infused into a liquid polymer. The tin plating or finish is then covered with a conformal coating comprising the liquid polymer. Then, one or more of the temperature and pressure of the conformal coating are adjusted to thereby create a dispersion of gas-filled voids comprising the gas in the conformal coating.

Abstract: An electrical component includes a conductive substrate, a tin layer formed on the substrate, and a coating of a foam formed on the tin layer to impede tin whisker growth, the coating comprising a foam having voids dispersed therethrough. A method for impeding tin whisker growth from a tin plating or finish formed over an electrical component includes covering the tin plating or finish with a coating of intumescent paint, and thereafter expanding the intumescent paint into a foam having voids dispersed therethrough.