Gaskets with Embedded Wires in Silicone and Fluorosilicone OW

Gaskets with embedded wires are a flat, sheet-silicone material, consisting of either foam or solid silicone rubber, with monel or aluminum metal wires embedded perpendicular to its surface. Excellent shielding performance and a high level of environmental sealing are achieved once compressed between two metal surfaces. The wires are knurled to facilitate compression and chemically bonded to ensure they remain held within the silicone or fluorosilicone carrier. They also penetrate most light-oxide layers, providing a low-resistance contact path when properly compressed. Variants are available in solid silicone (ZZ-R-765 2B 40), soft solid silicone, closed-cell silicone foam (AMS 3195), and solid fluorosilicone (Mil-R-25988 50), with differing numbers of monel or aluminum wires, allowing use across a wide range of applications for both galvanic compatibility and resistance to fluid contamination. The material is supplied in sheets up to 915 mm wide by 225 mm long, with a minimum thickness of 0.8 mm. The consistency of the soft solid silicone is significantly more uniform than foam, as there is no uneven cell structure that could affect moisture ingress and sealing force.

DELIVERY FORMS

• Die-cut gaskets
• Large molded gaskets
• Virtually any flat shape can be manufactured
• Sheet material
• Strip material available in continuous lengths
• Peel-and-stick backing for easy installation
• Gaskets can be equipped with stops or flanges to limit compression

DESIGN CONSIDERATIONS

Where possible, these gaskets should be designed with some form of compression stop. Compression stops in the form of flanges or posts should be integrated into the gasket to limit compression ideally within the 5–25% range, depending on gasket cross-section and enclosure design.

This material can require relatively high closing forces, so covers/enclosures must be sufficiently rigid and fastener spacing must be close enough to avoid poor sealing due to deformation of the gasket sealing surfaces.

AVAILABLE MATERIALS

Smaller gaskets can be die-cut in a single operation to minimize production costs. Larger gaskets are produced economically—without sheet-size limitations—from strips of material in the required finished shape, eliminating waste within the gasket. A fluorosilicone version is available for environments with fuels, oils, hydraulic fluids, and other contaminants. Solid silicone for applications where higher closing forces allow improved environmental sealing. Soft solid silicone or silicone foam for applications requiring lower closing forces.