A complete discussion of gasket materials and their use with a list of gasket manufacturers.
You will learn:
Gasket materials are a critical part of the manufacture of gaskets and determine a gasket’s function, endurance, strength, resistance to chemicals and fluids, and the conditions under which it is used. Gaskets are general use components designed to create a tight seal between elements to prevent leakage, seal connections, and block contaminants.
There are several factors that determine the choice of material for a gasket with pressure and temperature and the compatibility of a gasket with the application for which it is to be used. The general term gasket and gasket material covers a wide range of materials, configurations, and types due to the many applications where gasketing is necessary. The correct choice ensures that a process will function properly and efficiently without need for maintenance or repair.
Gaskets are made from a wide variety of materials due to their many functions. Each gasket and its material is designed to perform differently depending on the application for which it is being used. In the majority of cases, natural rubber and synthetic rubbers are the most common types of gasket materials with synthetic rubbers, such as silicone, being the predominant type.
Solid materials are typically an alternative to sponge materials. They are more durable and have a very low compression set, percentage of deformation under pressure. Solid gaskets are durable, strong, and long lasting due to the materials in their construction, which is two times longer than that of sponge materials. Solid materials can withstand a higher compression force than a sponge materials and are used in stressful and demanding applications.
Forming processes such as waterjet cutting, die cutting, and CNC cutting are used to form solid gaskets. Larger thicker solid gaskets are molded using injection molding.
Gaskets made from nitrile are meant for industrial applications with environmental extremes and high wear. Nitrile is a tough and durable material that also has resistance to chemicals such as oils and fuels. Other versions of nitrile can be used in food and agricultural applications.
Gaskets made from neoprene are more cost effective when compared to fluorosilicone and silicone. Neoprene is best suited for applications that need resistance to liquids like oil and water. Neoprene also has high resilience and elasticity, which makes it withstand elongation and tear better than silicones. It also has fatigue and abrasion resistance.
Gaskets made from Peroxide Cured EPDM are applied widely using rubbers with good weather, water, ozone, and UV resistance. As the Peroxide Cured EPDM is cured, heat stability makes the Peroxide Cured EPDM resistant to steam and extreme temperatures. The Peroxide Cured EPDM is less costly when compared to silicone depending on applications. However, Peroxide Cured EPDM is not best suited in applications prone to oil.
Butyl is a synthetically made rubber that is resistant to chemicals and oils. It resists moisture and does not allow gases to escape. Butyl is commonly used in medical and aerospace applications.
The fluoroelastomer is the premium choice of solid materials as it provides synergized benefits for all solid materials. Some of the benefits include resistance to chemicals and extreme temperatures. However, it is more costly than all the other solid materials. It is mostly applied in the aerospace industry, which needs all these properties.
Fluorocarbon gaskets have a flat cross section and are reusable for non-critical applications. They are widely used for applications that require frequent reassembly. Fluorocarbon gaskets are an alternative to copper gaskets and used to seal conflat flanges. They are not used for high temperature applications since they lose their strength with increased temperatures.
Gaskets made from sponge materials are used for low compression applications, such as when a housing assembly may bow or warp, with plastic housings, or when compression stops may cause cracking. Sponge material protects housing assemblies from compression forces and are sometimes preferred over solid materials due to their UL flame ratings. Silicone sponge material has a UL flaming rating of UL94V-0, which makes it more effective than solid silicone.
In applications that require a compliant and soft material, neoprene is the best choice. It is a cheaper option than solid rubber and other sponge materials. Its applications include shock absorption, weatherstripping, thermal barrier, and for basic sealing in industries. Neoprene has a closed cell structure making it impermeable to water. It is available in extra firm, firm, medium and soft densities.
The EPDM sponge has the same benefits as the neoprene blend. However, its resistance to ozone is greater, making it best suited in environments where exposure to ozone is a challenge. EPDM’s resistance to ozone makes it more expensive than neoprene.
Foam materials are similar to sponge materials in that they are recommended for use in applications with low compressional forces but can endure lower compressional forces in comparison to sponge materials. Foams are less expensive than solid or sponge materials and are used for simple seals for ducting and primary air. They do not provide a genuine environmental seal and are best suited for sealing two materials and not for critical applications outdoors.
Filter foams are custom designed to filter out dust. They allow air to flow in and out of a system and keep dust out . They are used in electronic applications where dust is undesirable.
Polyurethane foams can be used broadly in gasketing, energy absorption, and sealing and are less expensive than silicone foams. They have a low compression set. Polyurethane foams are available in a variety of densities and levels of firmness.
Polyolefin is an inexpensive material for basic gasket making. It is used as a space filler to prevent two sides of a part from touching.
Form in place is used where small gaskets are needed. Small gaskets are difficult to die cut and assemble. They are flimsy, have short longevity, and are difficult to place in assemblies. In such cases, form in place gaskets are used to reduce assembly costs. The gasket is dispensed into the unit and cured. FIP materials are typically used in electronic devices due to their size.
UV materials resist the effects of UV radiation, ozone, and weathering and are made of silicone, EPDM, and other fluoroelastomeric materials. During the production process, UV materials require limited curing time, which makes turn around times faster. UV materials are preferred where high volume and high throughput production are prioritized. Certain gasket materials are negatively affected by exposure to UV radiation, which affects their molecular structure causing them to break down and degrade. UV materials are designed for outdoor applications where exposure to UV radiation is common.
EMI materials are the most popular type of FIP gaskets used in various applications. They meet the requirements of the EMI applications and are best suited when precise and small gaskets are needed. EMI materials can shield between two gasket sides and can be used in satellites, aerospace, and test equipment.
EMI Shielding uses EMI materials to shield between the two areas of a part or product. Nickel Taffeta Foam is a form of EMI material that is used for applications that require low compression force. It’s used in applications that include electronics stacked in layers in servers and cabinets.
Microwave absorbing materials are dense foam and rubber based absorbers that are resistant to ozone, UV and high temperatures. They are thin and magnetically loaded with high loss at microwave frequencies but maintain elastomeric binders characteristics. Microwave absorbing materials are designed to lower the Q-factor in cavities as well as attenuating cavity oscillations. In as much as they are not really EMI materials, they are used in EMI applications to absorb frequencies from electronic component emissions instead of bouncing them back as EMI materials would.
Thermal interface materials are used for dissipating heat. The type of thermal interface material depends on the amount of power output over a time frame. Silicone is widely used for this type of gasket due to its high temperature capabilities. The right conductivity of the material needs to be chosen in order to dissipate the required heat. The more the heat dissipates, the more costly the material is. As with fluorosilicone, silicone materials may have cloth inserts to enhance their tear resistance.
Gap fillers acrylic has the same benefits as silicone gap fillers with additional properties to prevent outgassing. Unlike silicone, acrylic pad materials do not allow oil bleeding or siloxane VOC, which can cause device failure. The outgassing of silicone can be a source of contamination, especially in hard drives, which makes acrylic gap fillers more suitable for such applications as they are not prone to outgassing.
Thermal tape is best suited in creating a structural bond with custom gaskets. It is used to bond two sides of a part that need to be bonded together while dissipating heat. Thermal tape is used for bonding heatsinks to circuit boards.
Thermal pastes come in a wide range of thicknesses, unlike pre-formed gap filling materials. They do not need die cut shapes or specific pad thicknesses for different applications. In cases where low compressional forces are needed, thermal pastes can replace gap fillers. They don't pose any stress on components during assembly but are messy. Thermal pastes are a cost effective sealing method used in high volume applications where precision is not a priority.
The unique structure of silicone makes it ideal for the manufacture of gaskets. It is an inorganic synthetic polymer with a silicon oxygen structure that gives it exceptional strength and durability. The characteristic of silicone that differentiates it from other gasket materials is its ability to withstand extreme temperatures from -70°C (-94°F) up to 218.89°C (426°F).
The term silicone gaskets covers several types of gaskets that are designed to meet the needs of a wide range of applications. Aside from typical solid gaskets, silicone gaskets are available as sponge gaskets, expanded gaskets, and foam gaskets. Also included are electrically conductive silicone gaskets and chemical resistant fluorosilicone gaskets.
As a high performance gasket material, silicone forms a tight mechanical seal that fills space in any device. It is efficient at closing the gap between parts while offering a solid surface that complies with the configuration of the area where it is placed. Silicone gaskets are made to adhere to all industry standards, including ASTM, AMS, MIL, UL, RoHS, REACH, FDA, and USP Class VI.
Fluorosilicone (FVMQ) is a variation of silicone that is stable, compression set resistant to temperature extremes, and has exceptional resistance to solvents, fuels, oils, acids, and alkaline chemicals. It is from the trifluoropropyl group, which makes it a versatile material for sealing outdoor applications that are exposed to sunlight, ozone, chlorination, and hydrocarbons.
Fluorosilicone is more expensive than silicone due to its added features. It has a temperature range of -60°C up to 200°C (-76°F up to 392°F). What distinguishes it from silicone is its fluorocarbon content that makes it resistant to solvents,fuels, and oil.
To be conductive, fluorosilicone has a fluorinated silicone elastomer base that prevents degradation from harsh environmental conditions. A conductive filler, like nickel, aluminum, or copper, enhances fluorosilicone's conductivity. In cases where additional strength is required, fluorosilicone has cloth inserts added for tear resistance.
For special applications such as PCBs, fluorosilicone gaskets are used due to their resistance to hydrocarbons from harsh environmental conditions, just like silicone. As a chemical resistant material, fluorosilicone gaskets are used in processes that involve exposure to acetones or detergents.
Solid silicone gaskets are one of the most common forms of gasket and are made by die cutting or waterjet cutting and have a hardness range from 10 durometer up to 70 durometer on the Shore A scale. Low durometer silicone gaskets, 10 durometer, are used for low compression force applications while mid range to high range durometer gaskets, 30 durometer to 70 durometer, are used for higher compression force.
Silicone sponge gaskets are softer than solid silicone gaskets with some crossover to low durometer solid silicone gaskets. As with most silicone gaskets, the compression set for silicone sponge gaskets is low with a 2 psi to 5 psi compression force deflection. Silicone sponge gaskets can be open or closed cell with closed cell being the more common. The softness of silicone sponge gaskets creates a tight seal with low closure force at temperatures between 73.33°C up to 260°C (-100°F up to 500°F).
The high compressibility and soft material of silicone sponges makes them ideal for padding and gasketing. The material’s temperature resistance is well suited for outdoor applications. Closed cell structure silicone sponge gaskets prevent absorption of water and have an excellent compression set. Silicone sponge gaskets have a long useful life and are available in extra firm, firm, medium and soft densities.
Silicone foam material has many similarities to silicone sponge material. It is cured with liquid silicone and cast onto a smooth liner which gives the material a smooth skin. The structure of the material can be both open and closed celled with open cell being used for dust seals and vibration gaskets while closed celled are used for hostile environments.
As with many forms of silicone materials, silicone foam has resistance to extremes in temperatures. It is used in applications that require resilience, cushioning, sealing, vibration and insulation. The material is available in six varieties which range from ultra-soft to extra firm.
Silicone extrusions merge two types of gaskets, such as EMI shielding and environmental seal, into one product. The resulting material provides a thin shield that is electrically conductive and is co-extruded onto a silicone rubber base. Co-extruded silicone materials are used when there is a need to put a gasket into a grove. Where a grove is too small for extrusion, FIP is preferred. Extrusion yields a lower compression force because it is softer when compared to FIP dispensing.
EMI shielding silicone products are conductive as they have a conductive filler which can be nickel, copper, or aluminum. It is very flexible and can fit many designs and sizes, although it is not best suited for harsh environments such as sunlight or caustic chemicals that can impair the shielding and seal. EMI shielding silicone is used as connector gaskets or on printed circuit boards or electronics.
Gap filler silicone is used for customized gasket production for PCBs or chips applications. They are used where there is a gap between housings mated together that needs to be filled. The fap filler silicone gaskets are intended to transfer heat to housing made of aluminum which then dissipates heat.
Sil-pad materials are used where a silicone gap filler is preferred but the gap will be very thin. The use of the pads allows it to have the same material benefits while fitting into much smaller gaps.
The materials chosen to manufacture sealing gaskets take many forms and vary according to pressure and temperature capabilities. The general characteristics are described as flat, flexible materials that can tightly seal spaces between objects, parts, and surfaces. Although rubber is commonly thought of as gasket material, in reality, gasket material encompasses a wide range of materials that include cork, non-asbestos fibers, graphite, silicone, paper, and PTFE, to name a few.
Cork is a lightweight and stable material that resists water absorption. It has good compressibility, no lateral flow, and high resistance to oil. Factors that differentiate cork from other materials is its resistance to wear and being unaffected by high temperatures, which is an important gasket material property.
Cork and rubber gasket materials are made by combining granulated cork and synthetic rubber polymers. The materials have resilience with the flexibility of rubber and the compressibility of cork. The rubber content provides chemical compatibility, sealant properties, and resistance to weather conditions and acids. Rubber gasket materials are chosen based on chemical resistance requirements.
Natural rubber has excellent recovery properties and resistance to most inorganic salts, alkalis, and mild acids. It is not suitable for oils and solvents or when exposed to ozone, oxygen, or sunlight.
One of the special properties of natural rubber gaskets is their resistance to the effects of ultraviolet light, which makes them ideal for outdoor use.
Urethane gasket material ages well and is abrasion resistant but is not suited for extreme temperature environments. The waterproof properties of urethane make it ideal for stressful weather conditions. The most popular characteristic of urethane is its flexibility regardless of the temperature, which also enables it to conform to the needs of any application.
Neoprene is resistant to UV rays and ozone with tear strength and resilience although it can be severely damaged by petroleum based fuels. The material forms a permanent seal that cannot be broken. Neoprene’s flexibility and chemical stability over a wide range of temperatures are two of its outstanding characteristics. Added to neoprene’s strength and stability are its waterproof properties and corrosion resistance.
Gaskets are an essential part of industrial processes that form a mechanical seal in fluid processing. They prevent leakage and block contaminants from entering sensitive applications. The importance of gasket materials necessitates choosing the right material for an application. Engineers study gasket material characteristics to determine the correct material for a specific application.
Rubber’s formulations and grades are used in a wide range of applications depending on operating temperatures and environmental conditions.
Materials used in the formulations and grades of rubber:
rubber molding compounds are used in molding operations, such as transfer molding, compression molding, and injection molding. The different forms of molding compounds are used to create gaskets in different sizes and shapes.
Rubber molding compounds:
Closed cell sponge rubber has its individual cells closed from each other with each cell having its own elastomeric wall to produce the separation between the cells. The material is slower to recover from compression compared to open cell sponge rubber.
Closed-cell sponge rubbers are available in densities that range from soft, medium to hard. Open cell formulations and grades include:
The cells of open cell sponge rubber are interconnected without discreet or separated cell walls. The network of cells allows air to flow through to inflate the cells. When a compressive force is removed, the material rapidly regains its original form.
Formulations and grades for open cell sponge rubbers:
Non-asbestos fibers can be aramid or fiberglass that are merged with rubber. The formulation provides an exceptional pressure and temperature performance.
Formulations and grades for non-asbestos:
Cork has high flexibility and compressibility. The combination of cork and rubber, such as neoprene or nitrile, yields gaskets with resistance to solvents, oils, and fuels.
Materials used in the formulations and grades of cork:
Formulations and grades used for electrical insulation:
RFI/EMI Shielding materials are used in protecting electronic and electrical devices from radio frequency and electromagnetic interference.
Formulations and grades for RFI and EMI shielding:
Fiber includes a variety of fiber based materials which include insulating fiber, cellulose fiber, synthetic fiber and vegetable fiber.
Formulations and grades of fiber:
Foam materials are formed by gas trapped in separate or interconnected cells in a solid or liquid.
Formulations and grades of foam:
Felt is based on wool and is formed by exposing felt to heat, moisture, and pressure.
Formulations and grades of felt:
Flexible graphite gaskets have superior compressive strength and recovery with very little creep. Three common types of graphite gasket sheets are reinforced, pure, and laminated with some varieties of laminated gaskets available with an adhesive backing. Flexible graphite gaskets are resistant to a wide variety of chemicals and are used in cryogenic applications and high temperature applications of 426.67°C up to 454.44°C (800°F up to 850°F) with special grades able to withstand temperatures up to 537.78°C (1000°F). In oxygen free environments, flexible gaskets are capable of sealing up to 2982.22°C (5400°F). Flexible Graphite provides a high performance seal in extreme conditions such as high pressure and high temperature applications.
Although flexible graphite gaskets have very low mechanical strength, they can be reinforced by being combined with fiberglass or layers of metals, such as stainless steel, nickel, Inconel, or aluminum and fabrics like fiberglass or polymer films. Much like rubber, flexible graphite gaskets have excellent compressive strength and good recovery.
Applications for flexible graphite sheets:
Aside from its high temperature, pressure, and chemical resistance, flexible graphite acts as a heat spreader with excellent thermal conductivity. It also performs as an electromagnetic interference (EMI) shield to suppress unwanted noise and electrical currents.
The exceptional quality of flexible graphite makes it ideal for several types of high temperature applications that require a tight seal in critical conditions such as aerospace engines, heavy truck exhausts, and steam power plants. Flexible graphite sheeting is ideal as a sealing material for valves in addition to its thermal heat transfer or dissipation properties.
Flexible graphite is commonly used in a wide array of products and applications. Each flexible graphite gasket manufacturer has their own unique methods for identifying and classifying their products and provide information and data that assists in finding the flexible graphite sheets that can fit an application.
Polymers are enhanced by being mixed with different substances to achieve specific characteristics. Materials used include:
High temperature materials are materials that can maintain their mechanical properties at temperatures that exceed 500°C (932°F). The demands of modern manufacturing, with its high temperature processes, requires materials that are able maintain their stability under extreme heat. To accommodate this requirement, gasket manufacturers and chemists have developed an array of materials capable of meeting the required stipulations.
Formulations and grades of high temperature materials:
Spiral wound gaskets are capable of withstanding high temperatures and pressures as well as prevent leaks. They consist of an outer ring, inner ring, and sealing material.
There are many machines available to produce various materials suitable as gasket materials, such as rubber, cork, silicone, and fiber-based materials. These machines enable the efficient and precise manufacturing of gaskets, which are critical components used in industries such as automotive, aerospace, construction, and manufacturing to provide sealing and prevent leakage, ensuring the integrity and reliability of equipment and systems.
The FlashCut Gasket Cutting System from Atom FlashCut has likely gained popularity due to its precise cutting capabilities, versatile software, and the ability to handle a wide range of gasket materials. These features allow for efficient and accurate production, making it a preferred choice for gasket manufacturers.
Dieffenbacher's Fiberforge machine combines extrusion and lamination processes to produce gasket materials with continuous lengths, customized profiles, and excellent sealing properties. This innovative approach and the resulting high-quality output have contributed to its popularity.
The Zemat RCE Gasket Cutting Machine by Zemat Technology Group has become popular due to its efficiency, high cutting speed, and accuracy, allowing gasket manufacturers to optimize their production processes and meet demanding requirements.
Sutherland Presses offers gasket-specific compression molding presses, which have gained popularity for their precise control over temperature, pressure, and molding time. The ability to consistently produce high-quality gaskets with excellent sealing properties has made these machines sought after in the industry.
The Rolmacon Gasket Die Cutting Machine from Rolmacon Global Ltd is likely popular due to its accurate and efficient die cutting capabilities. By enabling high productivity and customization, this machine can meet the demands of gasket manufacturers seeking speed, accuracy, and flexibility.
Please note that specific models and features may have evolved since this last update. It is advisable to consult the respective manufacturers or industry resources for the most up-to-date information on the latest models and capabilities of machines used for producing gasket materials in the United States and Canada
Pressure sensitive adhesive (PSA) plays an integral role in the installation and use of gaskets. It is commonly applied to one side of gasket material. After which, it passes through a set of rollers that applies nominal pressure to bond the gasket and the PSA. The two forms of PSAs are transfer and double sided where transfer has adhesive on one side while double sided has adhesive on both sides.
Transfer PSA is a general purpose common form of tape that has a 0.002 inch layer of adhesive. Double sided PSA has that same thickness of adhesive on one side with a lower amount on the other side. The two sides of double sided PSA greatly increases the stability of a PSA and enables it to be used with gaskets.
The three forms of adhesives for PSA are acrylic, silicone, and rubber based. Unlike rubber based adhesive, acrylic based adhesives have moderate adhesion when first applied, which gradually builds. This factor gives it high shear strength that is greater than that of rubber based adhesives. Acrylic adhesive is superior to rubber bases in several factors, including high temperature resistance, solvent resistance, and durability. By comparison, which is a common attribute of silicone, silicone adhesives have a wider temperature range -62°C ( -80°F) to 232°C (450°F), a factor that makes silicone PSAs more expensive.
During production, PSA material is bonded to the gasket material before the gasket shapes are cut. The application makes gaskets easier to install, holds them in place, and allows for kiss cutting where the cutter cuts individual gaskets without touching the PSA release. Adding a pressure sensitive adhesive backing minimizes time and labor requirements when installing gaskets.
PSA is commonly used with neoprene and silicone gasket materials but does not adhere to PTFE that has a non-stick surface. As with gaskets, the PSA for a gasket must be carefully chosen in accordance with the type of gasket. Since gaskets experience high temperatures, pressure, and chemicals, a gasket’s PSA must be chosen accordingly. This includes the use of PSAs that comply with FDA regulations for food grade applications.
PSAs are commonly used with gaskets to provide an adhesive backing and increase the seal of a gasket. The purpose of a PSA is to improve the structural bond, act as an aid to manufacturing, and improve the adhesion of a gasket on an irregular surface. Although all these positive factors are admirable, they can be mute if the correct PSA is not chosen. A PSA adhesive system has to fit the requirements of an application.
Key considerations when selecting a PSA:
Multiple factors play an important role in the selection of a gasket for an application. The ability to withstand degradation and damage as well as the ability to stop air, gas, water, and fluids from escaping are primary concerns. Simply explained, gaskets are placed between surfaces that do not meet, and the surfaces are not perfectly flush or straight. The function of a gasket is to fill the gap such that fluids can flow through without loss or leakage. They are compressed between the surfaces to eliminate potential problems.
Temperature is the starting point when choosing a gasket material. This is because the temperature can change a gasket’s characteristics, including sealing properties, compression set, and maximum stress. Internal and external temperatures are important to consider because gaskets exposed to direct sunlight can experience internal temperatures that can go beyond 140°F. If a gasket is exposed to freezing temperatures, it can become stiff or brittle, making it prone to failure. When experiencing back and forth cycling from cold to warm, a gasket can end up having a high compression set.
UV and ozone exposure cause rubber gaskets to degrade. Electrical enclosures that have electrical components at high voltage can be a source of ozone. UV and ozone can break polymers’ carbon bonds drying, hardening, scaling, cracking, and flaking gasket material. Organic rubber gaskets such as Buna-Nitrile, natural rubber, and synthetic isoprene break down quicker. Silicone and EPDM have chemical blends designed to resist the effects of UV rays and ozone.
Joints are prone to deformation when pressure is exerted. A gasket material must be able to withstand such pressure. Some contemporary gaskets have a PxT rating factor that outlines the pressure and temperature maximum limits.
Industries such as automotive, aerospace, consumer, and electronics industries must adhere to product standards of the Federal EMI. Components and internal wires emit EMI and can function as emitting antennas. In controlling EMI radiation, electronic components are encased in conductive enclosures. The lid and the enclosure must have complete contact. Therefore, it is critical to choose an appropriate conductive gasket, which can be a source of EMI attenuation and environmental sealing.
The media a gasket will be exposed to is an important consideration. Generally, a liquid is much easier to seal compared to a gas. This can be considered once the temperature and pressure ranges have been decided on. There are chemicals that can affect the structural integrity and functional properties of the material. Thus, the gasket’s chemical resistance is vital. This has to be considered in relation to the temperature effect on the chemical resistance. Some fluids are aggressive when exposed to certain temperatures. Fluids sealed at an ambient temperature may not yield the same performance at higher temperatures.
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