Electromagnetic Compatibility EMC Components and Gaskets for RFI/EMI Shielding

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1 Electromagnetic Compatibility EMC Components and Gaskets for RFI/EMI Shielding For the latest up to date information and news please visit our web site 1

2 Introduction Exceptional EMC shielding and environmental sealing solutions Kemtron, a leading company in EMC shielding and environmental sealing since 1980, works with blue chip customers in more than 35 countries around the world. We have developed a global reputation for quality, performance and reliability, with an enviable track record in demanding industries such as defence, aerospace, information technology, communications and electronics. We help customers meet their EMC shielding and environmental sealing requirements with innovative solutions that enhance product performance, reduce through-life costs and ensure regulatory conformance. Our fully-equipped manufacturing and warehouse facility at Braintree in Essex has the flexibility to produce short-run bespoke solutions as well as standard products in volume. With in-house design, development, engineering and manufacturing capability, we maintain control over the entire production process to ensure the highest levels of quality and reliability. Financial stability Kemtron is an independent, financially-stable company with a healthy balance sheet and a clear market focus. Our five-year strategic plan provides a comprehensive framework for continuous improvement and commitment to the highest levels of customer satisfaction. Accredited to ISO 9001:2008, ISO 14001:2004 and OHSAS 18001:2007 EMC Components & Gaskets Kemtron has the knowledge, skills and resources to develop individual EMC solutions that match your exact requirements. This might take the form of custom-designed products or advice to your product development team on the design of enclosures and fixings to improve shielding performance. If you are designing new products, we recommend bringing in our technical team at an early stage in the development process. We can provide advice on design requirements that will ensure optimum shielding when used with the right EMC product. We can also develop solutions for retrofitted EMC products to overcome operational problems, improve shielding performance, or meet changing regulatory requirements. By working closely with many of the world s leading material producers, we can meet the demands of customers who want to meet everincreasing performance criteria or ensure reliable operation in extreme climatic, environmental or operational conditions. Environmental Sealing Overview With over 30 years experience in the environmental sealing industry, Kemtron has the knowledge, skills and resources to develop individual tailored solutions for new or existing products that match your exact requirements. We can also provide advice on design requirements that will ensure optimum protection when used with the right gasket or seal. We look at a wide range of factors including compression forces, chemical resistance and flame resistance that will impact sealing performance through the life of your product and work with you to design a solution that balances performance, reliability and cost. We are able to offer materials that have wide temperature ratings, long operational life, IP sealing, resistance to fluids and NBC chemicals, UL94 listings for fire retardancy and low toxicity products. 2

3 Contents Overview 4 Environmental Sealing Overview 135 What is EMC? 8 Environmental Sealing: Design Tools 10 Flat Gaskets 135 Conductive Elastomers: Form-in-Place 138 Materials Data 13 Silicone O Rings 140 Extrusions 18 Extrusions 143 O Rings 27 Sheet & Flat Gaskets 36 Form-in-Place Gaskets 39 Conductive Adhesives 42 Oriented Wires In Silicone & Fluorosilicone Rubber 45 Woven & Expaned Wire In Elastomers 49 Knitted Wire Mesh: Overview 52 Solid Knitted Wire Mesh 53 Over an Elastomer Core 57 With an Environmental Seal 63 Conductive Fabric Over Foam Gaskets 71 Beryllium Copper FInger Stock 78 Conductive Foam 91 Connector Gaskets for RFI/EMI Shielding 92 EMI Shielding Ventilation Panels: Aluminium Honeycomb Air Ventilation Panels for RFI/EMI Shielding 94 Aluminium Screen EMC and Dust Filter Ventilation Panels 112 Combined EMC and Dust FIlter Ventilation Panels 115 EMP Honeycomb Ventilation Panels 118 EMI Shielded Windows 120 EMI Shielding Cable Glands 124 Cable Shielding Jackets 125 Conductive Adhesive Tapes 128 EMI Shielding Laminates 130 Board Level Shielding Cans 132 Ferrites for EMI Suppression 134 3

4 EMC Components & Gaskets Overview Conductive Elastomers Knitted Wire Mesh Oriented Wires in Silicone Electrically conductive elastomers are made from silicone or fluorosilicone loaded with highly conductive particles such as silver plated aluminium, silver plated copper, nickel coated graphite and pure nickel. Available as extruded profiles, O rings, moulded components, and flat sheet for die cut gaskets. Conductive elastomers offer an excellent temperature range and are resistance to compression set and Fluorosilicone has superior resistance to fuel oils and solvents. Knitted wire mesh gaskets provide an excellent cost effective EMI gasket, providing shielding in the magnetic as well as electric fields. Kemtron knit in four wire types, Monel, Stainless steel, aluminium and tin plated copper clad steel. Knitted mesh gaskets can be supplied as solid mesh or knitted over elastomeric cores with or without environmental seal in continuous lengths or fabricated to custom designs. Solid and sponge silicone populated with vertically oriented monel or aluminium wires up to 140/sq cm. Provides excellent shielding with EMP survivability and will also provide an environmental seal. Available as sheet stock, strip or die cut to customer design and can be easily fabricated for large picture frame gaskets. Also available with self adhesive backing and compression stops or collars can be fitted to prevent over compression. Woven & Expanded Wire in Elastomers EMI Shielding Ventilation Panels Conductive Fabric Over Foam Gaskets 4 Woven aluminium wire or expanded monel or aluminium sheet impregnated with silicone, fluorosilicone or synthetic rubber. Provides an excellent EMI and environmental seal, the metal reinforcement eliminates cold flow due to over compression. Available as sheet or die cut gaskets, particularly suitable for MIL connector gaskets. Kemtron s EMI shielding vent panels or attenuvents are made from aluminium or steel honeycomb mounted into a frame. Many aluminium frame styles are available together with different thicknesses and configuration of honeycomb to meet different shielding requirements. Protective grills are available for vulnerable areas together with dust filtration foams. Many plated or painted finishes can be specified. Highly conductive nickel/copper or silver plated polyester or nylon fabric over an open celled urethane core. Many profiles are available including rectangular, D shape and low compression/deflection C shape seals. These provide an excellent EMI gasket with low compression set and excellent abrasion resistance for high cycling and wiping applications. Most meet UL94V-0 and are available as strips, cut to length or die cut.

5 EMC Components & Gaskets Overview Beryllium Copper Finger Stock Conductive Foam Form-in-Place Gaskets Beryllium copper EMI gaskets have superior mechanical spring characteristics and high electrical conductivity making them ideally suited to shielding applications where frequent access is required such as shielded room doors. These are available in profiles to suit most EMI shielding applications including grounding. Many plating finishes are available to address galvanic compatibility concerns and enhance shielding performance. Kemtron conductive foam is a low density PET and polyurethane foam which is copper + nickel coated throughout giving X,Y and Z axis low resistance electrical conductivity thereby giving excellent EMI shielding performance when used as an EMI gasket. The material is UL94V-1flame retardant. Conductive or non conductive elastomer silicone compounds are deposited as a gasket directly to the enclosure by XYZ CNC technology. These gaskets can be very intricate small sections suitable for enclosures with no space for a traditional gasket such as thin walled multi compartment housings providing an EMI and environmental seal. Connector Gaskets Kemtron has tooling for a wide range of standard MIL connector gaskets. Different materials are available to meet the demands of EMI shielding, environmental sealing, galvanic compatibility and fuel/oil resistance. Conductive Adhesive Tapes Available in a range of electrically conductive foils with conductive adhesive which are suitable for permanent shielding solutions or temporary fixes for EMC testing purposes. These can be supplied as a continuous roll in various widths or as die cuts shapes for specific applications. EMI Shielded Windows Windows for display devices or inspection panels providing optimum transparency and EMI shielding. These are made from fine stainless steel or copper wire mesh which is laminated or embedded within a range of optical substrates. They are made to order from small sizes up to architectural window size. Clear ITO coatings are also available. 5

6 EMC Components & Gaskets Overview Ferrites for EMI Suppression Cable Shielding Jackets EMI Shielding Cable Glands Kemtron stock a wide range of Ferrites for EMI suppression. Clip on cable cores suitable for retrofitting, cable cores for round and ribbon cables, common mode chokes. Most are available from stock or on short lead times. Zip on type tubing with internal EMI shielding liner for shielding of bundled cables. Easy to open and close so cables can be added or removed. Tubing is available in many diameters and is suitable for static or flexible applications. Flame retardant and low smoke/low toxicity versions are also available. Kemtron s cable entry gland provides an excellent EMI shield for screened cables which pass through enclosure walls. Made from brass they are available to suit cables from 1.5mm diameter up to 16mm. They also provide traditional strain relief for the cable. EMI Shielding Laminates Metal foils laminated to various non conductive backings, can be die cut to shape or scored and formed into a three dimensional shield. Laminates providing a cost effective light weight EMI shield that eliminate the need for conductive coatings on the inside of the enclosure. Microwave Absorber Absorber materials are used for EMI isolation and RF absorption. They are available in different materials to provide absorption from as low as 5MHz up to 40 GHz. Comprising materials such as loaded urethane, silicone, nitrile and neoprene, there are many choices available to provide products that can be characterised to provide absorption at single or multiple frequencies. Board Level Shielding Cans PCB shielding cans provide effective isolation of board level components. Photo etching is the most cost effective production method and being custom made, the cans can be manufactured to incorporate a range of design features to suit individual applications. Our sales department should be contacted to discuss requirements. 6

7 Environmental Sealing Overview Conductive Adhesives Materials Flat Gaskets Single component RTV (room temperature vulcanising) silicone electrically conductive adhesives are available with a range of fillers from silver to nickel coated graphite. These are designed to be used as a thin bond between two components, caulking compound can also be supplied for larger gap filling. Two component epoxy systems are also available. Kemtron stock many types of elastomeric materials for flexible environmental sealing but specialising in silicones, fluorosilicones, solid and sponge that meet UL94V-0 and low smoke/ low toxicity. Other materials include Poron polyurethane, Neoprene / chloroprene, EPDM etc. Materials can be supplied as sheet, strip, laminated, self adhesive backed or die cut to complex shapes. Liquid RTV silicone can be applied as a form in place gasket direct to customer s hardware. Flat gaskets can be cut by rule die, kiss cut or more complex shapes by water jet cutting. Compression stops or collars can also be incorporated, this leads to reduced hardware costs and negates the need for fixings to be torqued to prevent over compression and damage to the gasket. Self adhesive backing can be applied to the materials prior to cutting. Extrusions Extruded profiles include cords, tubes, D shape, hollow D, P shape and bespoke profiles to special order. Flat strips can be extruded or slit from sheet. Materials include silicones, fluorosilicones, Poron urethane foams, EPDM, Neoprene etc. Extrusions can be supplied as continuous length or fabricated into O rings or more complex gaskets. O Rings Kemtron specialises in the manufacture of bespoke O rings specialising in silicones and fluorosilicones. Made from extruded sections cut to length and the two ends joined by vulcanisation to ensure a durable bond and maintaining the integrity of the seal. Sections and materials available are sponge, hollow tube, solid, D shape, rectangular etc. Rectangular picture frame gaskets with mitred corners can also be made in this way. 7

8 Design Tools Electromagnetic Compatibility (EMC) What is EMC? The definition of EMC is the measure of equipment s capability to neither conduct electromagnetic energy nor radiate it. The equipment in turn should not be susceptible to any conducted or radiated emissions from any other source. The two most important characteristics of electromagnetic waves connected with interference are the amplitude and the frequency of the waves. Interference Control The three main ways in which interference factors can be controlled are:- Using filtering techniques to filter out unwanted frequencies and thus prevent them from travelling along signal and input lines. Reduction of the wave s amplitude by careful circuit design and component layout. Prevent radiation emission to or from the equipment by the use of suitable components and materials to give EMI screening. The first approach towards good design is to insert low pass LC filters into the input and output lines to the equipment. The filters will divert any emanating interference along the lines to earth. The next concern is to design the various sections of the equipment to ensure that sections capable of radiation are isolated from each other by the use of careful PCB layout and the use of metal screens wherever required. The equipment will then need to be shielded to prevent the ingress or egress of electromagnetic radiation. This is done by the use of suitable conductive gaskets. Kemtron Ltd specialise in the manufacture and supply of suitable gaskets, components and materials. EMI Shielding The EMI shielding of any enclosure involves all of the internal and external openings and components. The openings consist of covers, panels, doors. The components are panel meters, displays, indicator lights, connectors, switches, potentiometers, etc. The success of EMI shielding an enclosure depends upon the correct selection and application of the screening materials available. To this end Kemtron are in a position to advise you on the correct materials related to your problem. Effective Shielding Several reasons exist to create effective shielding of equipment. Among the more important benefits are:- To minimise radiation and thereby prevent interference with other sensitive areas or equipments. To reduce any radiation to a level this will make it safe for life for example, microwave ovens. To prevent unwanted reflections inside equipment which could cause it to malfunction. To ensure electrical and mechanical compatibility with the metal enclosure. To meet local and international EMC legislation. 8

9 Electromagnetic Compatibility (EMC) Electrical The electrical requirements are covered by measurements made to ascertain the level of attenuation required to fulfil the figures laid down in the appropriate specification over a specified frequency band. The data given in the catalogue outlines the typical attenuation versus frequency of the various materials when correctly fitted. These figures are corroborated by independent tests. Mechanical The mechanical considerations are of the utmost importance in the fitment of shielded gaskets. The design of an EMI shielded enclosure should be undertaken as if the gasketing will be required. If it is determined at a later stage that a particular gasket is not required it is easy to leave this out. If no provision for the gasket is made and then later required the modification to implement a gasket can be time consuming and costly. The most effective shielding is provided when a continuous metal to metal contact is achieved. The metal surfaces of any enclosure flange are never 100% flat unless machined to very high tolerances. The function of the gasket is to take up any differences which may exist between the surfaces. The type of gasket material and thickness is thus selected according to the tolerances with which the enclosure or panel is fabricated. To ensure metal to metal contact the design should incorporate, wherever possible, a means to prevent the over compression of the gasket and thus ensure evenness of pressure. It is very important when fitting conductive gaskets that all contact surfaces be free from contamination and be highly conductive. The surfaces must therefore be free of paint, greases etc. and thoroughly cleaned prior to fitment of the gasket. Chemical Two dissimilar metals in the presence of an electrolyte e.g., sea water. will act as a battery and create a flow of electric current. This effect can cause corrosion and could affect the resistivity of the gasket material reducing its efficiency. In order to minimise or prevent galvanic action it is important to select compatible metals. Environmental Often equipment will need to operate in conditions where the ingress of moisture would be hazardous to the correct functioning of the system. To prevent this, an extra non conductive gasket acting as an environmental seal can be incorporated into the design of the enclosure. A more practical solution is to use an EMI shielded gasket which incorporates an environmental seal. There are a variety of types available. 9

10 Design Tools Bi-Metallic Corrosion Because of the number of variables that contribute towards electrolytic or bi-metal corrosion, it is not practical to illustrate all possible situations and therefore the following data should be used for guidance only. If more definitive evidence is required, then we suggest that a test be conducted, employing the materials to be used and analysing the results. As a general rule the less noble metal corrodes leaving the more noble metal intact, for example, if aluminium and silver are in contact in the presence of a suitable electrolyte a current will flow, resulting in severe corrosion of the aluminium. It should, however, be remembered that many metals are protected from corrosion by natural oxide or passive films and unless these are broken down then they will behave as if they are more noble than their electro potential would suggest. Furthermore the geometry and the relative surface areas of the contacting metals can have a marked reaction on the overall corrosion reaction. Environmental Conditions A Internal equipment housed in a room protected from the outside environment. B External equipment housed outside in a marine atmosphere. C Equipment immersed in seawater. Corrosion Effect 1 Severe corrosion may occur between contact material and gasket. 2 Fairly severe corrosion may occur between contact material and gasket. 3 Slight corrosion may occur between material and gasket. 4 Very slight or no corrosion may occur between contact material and gasket. Gasket Type Monel Silver Berrylium Copper Stainless Steel Tinned Coppered Steel Aluminium Environmental ABC ABC ABC ABC ABC ABC Condition Contact Metal Aluminium Brass Cadmium Carbon Iron Chromium Copper Phosphor Bronze Nickel Silver Stainless Steel Tin Zinc

11 Design Tools UL94 Flammability Ratings Many of Kemtron s EMC and Environmental products are offered with UL94 flammability ratings. The following chart may prove helpful when deciding the level required. Please note that we can only supply products rated as indicated in the individual data, other ratings are given for convenience. UL94 Flammability Ratings explained 5VA Surface Burn 5VB Surface Burn V-0 Vertical Burn V-1 Vertical Burn V-2 Vertical Burn H-B Horizontal Burn Burning stops within 60 seconds after five applications of five seconds each of a flame (larger than that used in Vertical Burn testing) to a test bar. Test specimens MAY NOT have a burn-through (no hole) This is the highest (most flame retardent) UL94 rating Burning stops within 60 seconds after five applications of five seconds each of a flame (larger than that used in Vertical Burn testing) to a test bar. Test specimens MAY HAVE have a burn-through (a hole) Burning stops within 10 seconds after two applications of ten seconds each of a flame to a test bar. NO flaming drips allowed Burning stops within 60 seconds after two applications of ten seconds each of a flame to a test bar. NO flaming drips allowed Burning stops within 10 seconds after two applications of ten seconds each of a flame to a test bar. Flaming drips ARE allowed Slow horizontal burning on a 3mm thick specimen where the burning rate is less than 3 inches / minute or stops burning before the 5 inch mark. H-B rated materials are considered self-extinguishing. This is the lowest (least flame retardent) UL94 rating 11

12 Design Tools Storage and installation of Kemtron gaskets with self adhesive backing Storage: Gaskets should be stored in original packaging at room temperature at 20 C and at relative humidity of 50%. Application: Gaskets should be applied to a smooth, clean and dry surface. Clean the surface with a suitable solvent such as isopropyl alcohol to remove oils and contamination. Ideal application temperature range is 20 C to 38 C, application to surfaces at temperatures below 10 C is not recommended as the adhesive is too firm and will not wet the surface. Once properly applied, low temperature holding will be satisfactory. Remove the backing film, and then make sure the gasket is correctly positioned and press down firmly to ensure a good bond over the entire mounting surface. Avoid any repositioning as this will reduce the effectiveness of the adhesive and may distort the gasket. Allow 24hrs for the adhesive to cure and reach its maximum bond strength. 12

13 Conductive Elastomers: Materials Data Product Overview Conductive Elastomers are fully cured silicones or fluorosilicone loaded with a variety of highly conductive particles providing superior EMI/RFI shielding performance combined with excellent environmental sealing. The various conductive fillers are designed to ensure galvanic compatibility whilst providing low contact resistance between mating surfaces. Kemtron s many years of manufacturing experience combined with quality control and compliance testing ensures our Conductive Elastomers are suitable for the most demanding situations, offering consistency time after time. Application Industrial controls. Instruments. Military equipment. Avionics. Medical electronics. Electronic equipment enclosures. Availability Highly conductive EMI/RFI gasket and environmental seal. Extrusions. Flat gaskets. O Rings. Sheet. Thickness from 0.5mm. Wide temperature range -55 C C. Fluorosilicone for harsh environments: Fuel oils and solvents. Choice of materials for galvanic compatibility. Flame retardant to UL94VO. Conductive self adhesive backing on sheets. 13

14 Conductive Elastomers: Materials Data Technical Specifications Material Selection Kemtron manufacture conductive elastomers using four standard highly conductive fillers in both silicone and fluorosilicone variants, all have slightly different attributes: Conductive fillers available for Silicone and Fluorosilicone Nickel Plated Graphite A high quality cost effective commercial material with increased use in the military markets. Easily extruded or molded. SNG FR grade to UL94 V0. Silver Plated Aluminium An excellent grade high performance material widely used for higher frequency applications in the commercial and military markets. Lighter in weight than some other materials. Silver Plated Copper This material offers excellent RFI/EMI shielding performance across the frequency spectrum, but comes at a higher price and with increased weight. Nickel This product has largely been replaced by Nickel Graphite but is still widely used in military and aerospace applications. Fluorosilicone has better aging properties than the silicone. A good performer at lower frequencies but also heavier than some other materials. Silicone (VMQ) Silicone rubber is used because the end use requires a material that retains its elastomeric properties over a very wide range of temperatures and does not degrade due to the presence of oxygen and ozone. Silicone elastomers do have weaknesses in their properties and behavior. In comparison with other elastomers their tensile, tear and abrasion properties are significantly poorer, however, they do not decay as the temperature is increased and above 150 C they become on the whole better. The swelling and chemical resistance of silicones is comparable to those of chloroprene rubber, they are not affected by aliphatic oils however they swell in napthenic and are attacked by hot aromatic oils. Silicones main weakness is to hydrolytic attack and decomposition especially to steam between 120 C and 140 C, they are also susceptible to attack by acids and alkalis. Production Capabilities Kemtron s extensive manufacturing facilities combined with our development team, Quality control and experienced manufacturing personnel enable us to be one of Europe s leading manufacturers of electrically conductive elastomers. Here at Kemtron we develop, test, compound, mould, extrude and vulcanize conductive elastomers. This enables us to be flexible in our approach towards customer satisfaction. In addition to our standard range, we can develop and compound new grades of materials at our facility in the UK to meet customer specific requirements, subject to economic minimum quantities. Materials Material Code SNG FNG SNG-FR SSA FSA(70) SSA (65B) SSC FSC SN FN Fire retardant materials Material Silicone Nickel Graphite Fluorosilicone Nickel Graphite Silicone Nickel Graphite Flame Retardant UL94 VO Silicone Silver Aluminium 65 Shore A Fluorosilicone Silver plated Aluminium 70 Shore A Silicone Silver Aluminium 65 Shore A Blue Silicone Silver Copper Fluorosilicone Silver Copper Silicone Nickel Fluorosilicone Nickel Silicone Nickel Graphite flame retardant material SNG-FR is tested and approved by Underwriters Laboratories to UL94 VO file number E Fluorosilicone (FVMQ) Fluorosilicone is used because it overcomes the formers chemical resistance and swelling weaknesses whilst retaining on the whole the excellent high temperature properties. FVMQ however still suffers from attack by high temperature steam and hydrolysis by both acids and alkalis.

15 Conductive Elastomers: Materials Data Technical Specifications (Continued) Test Results Listed below are the test results of Kemtron s Electrically Conductive Silicone Elastomer materials. Some tests are performed in house and others by external laboratories all using calibrated equipment, testing to the standard specified in MIL-DTL Kemtron offer the performance data and methods of testing to MIL-DTL for comparison only. All of Kemtron s test certificates and reports are available upon request. The results were obtained in laboratory conditions and should be used as a guide only. Customer hardware and many other factors are beyond our control. Therefore customers should perform their own tests to ensure suitability of the product for the desired performance. Kemtron recognises the importance of quality and consistency in conductive elastomer seal manufacture. With this in mind; We specify, batch control and trace all raw materials. Control compounding with robust procedures and batch test every mix with calibrated test equipment to ensure batch to batch consistency and conformance to our published data sheets. Use certified and approved outside test laboratories. Batch control and trace all manufacturing including materials, tools, equipment and operators. The controls are embedded into our accredited management system that we have held since All the above is overseen by our QA department and our in-house qualified Polymer Engineer / Chemist ensuring proven consistency and traceable results. Test Description Elastomer Binder SNG VMQ SNG-FR VMQ SSA VMQ SSA65B VMQ SSC VMQ SN VMQ FNG FVMQ FSA70 FVMQ FSC FVMQ Material Performance Conductive Filler Ni/C Ni/C Ag/Al Ag/Al Ag/Cu Ni Ni/C Ag/Al Ag/Cu Ni Colour Dark Grey Light Grey Tan Blue Tan Dark Grey Dark Green Light Green Green Dark Green Volume Resistivity MIL-DTL (ohm-cm, max.) As supplied (without Pressure sensitive adhesive) Hardness( Shore A ±7) ASTM D2240 Specific gravity (±13%) ASTM D792 Tensile strength (lb./in. min) ASTM D412 Elongation % ASTM D Tear Strength (lb./in. min) ASTM D624 Compression set ASTM D C (%,) Method B Compression / deflection ASTM D575 method B 100PSI on 1.58mm% Operating Temperatures Max C Min C Shielding Effectiveness MIL-DTL (db) 20 MHz 40 MHz 60 MHz 80 MHz 100 MHz 200 MHz 400 MHz 600 MHz 800 MHz 1 GHz 2 GHz 4 GHz 6 GHz 8 GHz 10 GHz Electrical Stability After Break (Ohm-cm, max) Heat Ageing MIL-DTL hours at 1.25 x max Operating Temperature Ohcm-cm, max FN FVMQ

16 Conductive Elastomers: Materials Data Technical Specifications (Continued) Properties of elastomers that can be measured and how they impact on selection of the appropriate material for gasket/sealing purposes Hardness Hardness is a measure of the degree of indentation when an indenter of known geometry is placed on the elastomeric surface under a known constant force for a fixed time. The different scales used Shore A and IRHD are defined by the form of the indenter, applied load and time of reading after indenter application. In a standard elastomer there is reasonable agreement between observed hardness and Young s Modulus (E). In the case of conductive elastomers this relationship is not so clear cut since the elastomer acts more as a binder for the filler and the hardness appears to have a rule of mixtures response. Compression set Compression set (or more correctly permanent set after compression to a fixed strain) should not be confused with either Creep or Stress Relaxation. The test was originally conceived as a measure of state of cure. The test basically involves compressing a cylinder of material to a fixed strain and leaving it for a known temperature for a fixed time. The compression is removed, the cylinder allowed to recover over a fixed time and the height re-measured. The value recorded being the percentage difference according to the equation below; Compression set at Constant Strain = to tr x 100 to ts Where to tr ts is the original thickness is the thickness after recovery is the deflection applied (thickness of shim) Hence, the test as originally conceived would be carried out on test pieces cured for varying times at a fixed 16 Tensile strength and elongation at break Tensile strength and elongation at break are obtained from the same standard dumbbell shaped test-piece punched from a moulded sheet of rubber of known thickness. By use of tensile test equipment fitted with an extensometer a stress v strain response curve can be obtained and a judgement of the stresses and strains that can be made on the material during service made. Tear The tearing properties of a material are obtained using tensile test equipment and a standard test piece of known dimensions. Tests are carried out in tension and the results reported in terms of load required per distance moved by the tear tip. temperature and the correct cure determined from where the compression set value was found to be a minimum. Although the original purpose of the test has been superseded by modern rheometers the test continues to be used. The reason for this being the belief that the test gives an indication of creep which can be seen below is not strictly true. Since the test is an amalgamation of that used to assess creep and stress relaxation. Creep also known as cold flow Creep is defined as the change in strain with time whilst the elastomer is held under a constant stress. This stress can take the form of compression, tension and/or shear. In terms of how creep applies to a seal or gasket, this is dependent on whether it is constrained or nonconstrained. In the non-constrained environment the strain within the elastomer will increase with time until in theory the stress within the elastomer reaches a minimum. The elastomer seal/gasket will compress and spread out. In the constrained environment the seal/ gasket will conform to the groove allowed and the creep arrested.

17 Conductive Elastomers: Materials Data Technical Specifications (Continued) Stress relaxation Stress relaxation is defined as the change in stress with time whilst the elastomer is held under a constant strain. Consider that you have a seal that during installation is compressed by 10% of its original thickness. To obtain this 10% compression requires 100 MPa, and you can consider that the elastomer is exerting 100 MPa in return and the seal would be able to retain internal and external forces of 100 MPa. However, with time and ageing the stress exerted by the elastomeric seal can decay i.e. it may only exert 90 MPa yet still be compressed by 10%. The paragraph above describes the reality of Stress Relaxation in compression the other two modes of tension or shear can also be measured. Certain schools of thought recommend that stress relaxation issues can be overcome by increasing the initial compression the seal / gasket is taken to by 25% in the expectation that stress relaxation will occur and the operational force will be that required. This approach obviously assumes that the seal/gasket will be able to withstand the extra strain and the seal/gasket behavior to the extra stress remains the same. Consideration must also be given to whether it is retained in a groove or free to take up a natural form on deflection. Compression deflection This test is carried out using a disc of the gasket/seal material of a known thickness and diameter to which is applied a load equivalent to 100 psi and the deflection measured. Accelerated ageing tests In general any of the above tests can be carried out on test samples either aged or cut from test sheets which have been exposed to air ageing at an elevated temperature. Such tests may give an indication of how the material will perform in the long term in the service environment. Standard Tests Specific to Conductive Elastomers Volume resistivity In this test a sample of the conductive Elastomer whose dimensions are known is put under compression to a known strain. The difference between the known applied current is compared to that flowing through the Elastomer and the resistivity of the Elastomer. Volume resistivity after extension/break This test is the same as that for volume resistivity except that the sample is punched from the central strip of a dumbbell that has been stretched to break and then allowed to recover for thirty minutes. This test gives an indication of the behavior of the material if it is stretched during installation or is re-used during servicing. Dynamic volume resistivity In this test the variation in the volume resistivity is measured whilst a sample of known dimensions is put under a fixed load. The load is then oscillated around this fixed point by a known amount over a range of frequencies and the volume resistivity recorded. The purpose of this test is to give an indication as to how the seal/gasket will perform in service when the vibrations from equipment operations are imposed upon it. Conductive Silicone & Fluorosilicone Elastomers Product Handling & Storage Conductive elastomer products are expected to provide a service life of many years. However, if the product is to be stored, certain factors may have a detrimental effect. Kemtron recommend that the following precautions are carefully observed to ensure product longevity: Handling These materials should not be subjected to stretching in either storage or installation otherwise the conductive particles may disperse in the rubber, resulting in degradation of the shielding performance. In addition materials should be handled using cotton gloves to prevent surface contamination. Extra care must be used when fitting gaskets into channels, especially O rings. The product should be eased into the final groove shape from each end or opposite diagonals, working slowly inwards or round the outside. It must not be placed in at one end and simply pushed in along the length, this will stretch the gasket and leave excess material. If in doubt please contact us for our recommendations. Storage temperature It is recommended that the product be stored at normal ambient temperatures. Exposure to light & UV Exposure to any UV source (i.e artificial or natural light) should be avoided if possible. It should be kept stored in light proof, sulphur free packaging. Method of storage The material must be stored without any stretching or crushing. It is best kept in light proof, sulphur free polythene bags or light proof, sulphur free boxes. Contact with other materials The product should not be allowed to come into contact with Solvents, oils & greases, PVC, any material containing sulphur, dissimilar rubbers or metal containers. 17

18 Conductive Elastomers: Extrusions Product Overview Kemtron manufacture a wide variety of profiles from our standard tooling. We are also able to produce to your exact requirement with minimal tooling cost. Extruded profiles are available in continuous, cut lengths or fabricated to your requirements, such as rectangles by vulcanizing the joints. This process uses the same conductive polymer compound. Ensuring complete electrical conductivity is maintained across the joints. Please see O ring section. Design Considerations When selecting a profile it is important to give attention to the mechanical design of your product. Round and D section seals should ideally be mounted in a suitably sized channel or groove. If the gasket is to fit in a groove. It is important that the gasket size chosen does not overfill the groove, when using solid sections you should ensure that the groove cross sectional area is a minimum of 5% greater than the proposed gasket cross section. See grove design data. Attention must also be paid to the closing force required to compress the gasket to the working height required. Self adhesive backing can be supplied on some flat profiles and usually only partially covers an area of the extrusion. Available as conductive (CSAB) or non conductive (SAB). This adhesive is an assembly aid only. 18

19 Conductive Elastomers: Extrusions Technical Specifications Round Tubular Profile 1201 Profile 1202 OD mm ID mm Part Number Diameter Part Number XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX

20 Conductive Elastomers: Extrusions Technical Specifications (Continued) 20 OD mm ID mm Part Number XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX

21 Conductive Elastomers: Extrusions Technical Specifications (Continued) OD mm ID mm Part Number XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX

22 Conductive Elastomers: Extrusions Technical Specifications (Continued) OD mm ID mm Part Number XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX

23 Conductive Elastomers: Extrusions Technical Specifications (Continued) Solid D Hollow D Profile 1203 Profile 1204 Width A Height B Part Number XXX XXX XXX XXX XXX XXX XXX XXX XXX Width A Height B Wall C Radii R Part Number XXX XXX XXX XXX XXX XXX

24 Conductive Elastomers: Extrusions Technical Specifications (Continued) Channel Flat Strip Profile 1206 Profile 1207 DIm A Dim B Dim C Dim D Part Number XXX XXX XXX XXX XXX XXX Dim A Dim B Part Number XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX

25 Conductive Elastomers: Extrusions Technical Specifications (Continued) Hollow Rectangular How To Order Select chosen profile and size from our extrusion section then insert the material code XXX (1201-XXX-0030). e.g. Profile 1208 DIm A Dim B ØC Part Number XXX XXX Tolerances Up to 2.0mm ± 0.1mm 2.0mm to 5.0mm ± 0.15mm 5.0mm to 9.0mm ± 0.2mm Materials Material Code SNG FNG SNG-FR SSA FSA FSA(70) SSA (65B) SSC FSC SN FN Material Silicone Nickel Graphite Fluorosilicone Nickel Graphite Silicone Nickel Graphite Flame Retardant UL94 VO Silicone Silver Aluminium 60 Shore A Fluorosilicone Silver Aluminium 60 Shore A Fluorosilicone Silver plated Aluminium 70 Shore A Silicone Silver Aluminium 65 Shore A Blue Silicone Silver Copper Fluorosilicone Silver Copper Silicone Nickel Fluorosilicone Nickel 1201-SNG-0030 Silicone nickel graphite 3.0mm dia cord Gaskets in Grooves For the typical electronic enclosure, groove mounted gaskets are better than surface mounted gaskets because when the gasket is compressed in the groove the two mating flanges can come into contact with each other thereby enhancing the EMC performance with the advantage of the groove acting as a compression stop and therefore protecting the gasket from damage at the same time. Solid and Hollow Gaskets in Grooves Because solid and tubular style gaskets, when compressed, cannot change their volume the groove has to be larger in width to accommodate the change in shape, otherwise severe gasket damage can be caused when the flanges are fixed together. This can result in loss of compression on the gasket and compression set occurring. This will give a reduction of shielding effectiveness, coupled with the possibility of environmental leakage. The groove width should be from 5% to 35% larger than the gasket width, but this is dependent upon the gasket profile being used. For example, a round section gasket has less volume than a square section gasket of the same diameter/ width. The important factor is that in the worst case of high tolerances on the gasket size versus low tolerances on the groove size is that when the gasket is compressed by both flanges, it fills the available space by no more than 100%, i.e.: the volume of the accommodating groove with both flanges touching should be equal to, but be no less than the volume of the gasket cross section. Knife Edge into Grooves with Tubular Gaskets Large applications, such as cabinets, may use a tubular type gasket fitted into a groove and the mating flange known as a knife edge. The knife edge plunges into the gasket causing the seal. With tubular gaskets the knife edge collapses the gasket rather than compressing it. The knife edge should not penetrate the gasket by more than 50% of its diameter or there may be a danger of the gasket being unable to recover due to the excess pressure applied by the knife edge. 25

26 Conductive Elastomers: Extrusions Technical Specifications (Continued) Gasket Groove Sizes Cord Diameter mm 15% Compression 20% Compression Depth Width Depth Width The above cross sectional area groove sizes allow for the free movement of the gasket when being compressed. This method of calculation ensures that the volume of the gasket does not exceed that of the groove when fully compressed, resulting in groove overfill. This also minimises the amount of compression force required to achieve a good RFI/EMI seal. It is important to note that when designing in an EMC gasket, that the principles of O ring design for pressure sealing do not apply. The groove depth dimension is the most important, as it is this that limits the gasket compression. The groove width has no maximum dimension and is only there for gasket location purposes. Tighter groove dimensions using volume calculations may be employed to enhance environmental sealing. However this will increase the compression forces required. Because there are so many variables with tube cross sections it is difficult to give precise information on this subject. Kemtron are able to supply samples for evaluation purposes. Compression % Cord Diameter mm Force per 100mm N 24N 35N 47N N 43N 68N 94N N 66N 110N 154N N 105N 146N 196N Tolerances Up to 2.0mm ± 0.1mm 2.0mm to 5.0mm ± 0.15mm 5.0mm to 9.0mm ± 0.2mm It is also important to consider the tolerances of the gasket and the groove. Compressed Gasket Internal Bend Radius Casting With Solid Cord Gasket The minimum internal bend radius of a solid cord gasket is 1.5 x cross section of cord. Casting With Tube Gasket 26 The above calculations are based on reducing the depth of the groove by a given compression % and increasing the width by the same amount less 5% EG: 20% reduction in depth 15% increase in width. When choosing a tube section as a gasket it is recommended that consideration be given to the lower compression forces, making sure that there is enough resilience in the gasket to ensure a good RFI/EMI seal. In these cases it is sometimes better to use the volume groove size calculation, with the groove side walls offering support for the tube. The minimum internal bend radius of a tube gasket where the id of the tube is no greater than 30% of the cross section is 2.5 x cross section of tube.

27 Conductive Elastomers: O Rings Product Overview Kemtron s experience in the manufacture of O rings is vast, our preferred method of production is extruded and jointed. We have a huge selection of vulcanizing tools to suit our standard extrusions. The jointing process uses the same conductive polymer compound ensuring complete electrical conductivity is maintained across the joints. Moulded versions are available if specifically requested. Both silicone & fluorosilicone with all varieties of conductive fillers are available for the manufacture of O rings. Advantages Of Vulcanised O Rings Cost effective. No tooling costs. Reduced lead times. Better surface finish (zero flash). Allows hollow sections to be used for lower compression force. Custom lengths easily produced. Tight tolerances on developed length and cross section. Vulcanised O rings with a ID as small as 10mm depending on cord diameter. Design Considerations When selecting a profile it is important to give attention to the mechanical design of your product. Round and D section seals should ideally be mounted in a suitably sized groove. If the gasket is to fit in a groove. It is important that the gasket size chosen does not overfill the channel, when using solid sections you should ensure that the groove cross sectional area is a minimum of 5% greater than the proposed gasket cross section. Attention must also be paid to the closing force required to compress the gasket to the working height required. 27

28 Conductive Elastomers: O Rings Technical Specifications 28 Tolerances Up to 2.0mm ± 0.1mm 2.0mm to 5.0mm ± 0.15mm 5.0mm to 9.0mm ± 0.2mm Developed length ± 1.5mm = less than ±0.5mm on diameter Standard Vulcanized Cord O Rings Material Material Code Silicone Nickel Graphite SNG Silicone Nickel Graphite Fire Retardant SNG-FR Fluorosilicone Nickel Graphite FNG Silicone Silver Aluminium SSA Silicone Silver Aluminium 65 Shore Blue SSA (65B) Fluorosilicone Silver Aluminium 70 Shore FSA (70) Silicone Silver Copper SSC Fluorosilicone Silver Copper FSC Silicone Nickel SN Fluorosilicone Nickel FN Standard Cord Cross Sections Section Reference 1.00mm mm 1.20mm mm 1.30mm mm 1.40mm mm 1.50mm mm 1.60mm mm 1.80mm mm 2.00mm mm 2.20mm mm 2.40mm mm 2.50mm mm 2.60mm mm 2.80mm mm 3.00mm mm 3.20mm mm 3.50mm mm 3.80mm mm 4.00mm mm 4.30mm mm 4.50mm mm 4.80mm mm 5.00mm mm How to order Minimum Inside Diameter of O Ring Select the material from the list and insert the material code followed by the section reference and finally the inside diameter. (1301-XXX-XXXX-XXXX) e.g SSA Vulcanized O Ring Silicone Silver Aluminium 1.6mm cross section 35.5mm internal dimension Standard Inside Diameter Of O Ring XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX-0405

29 Conductive Elastomers: O Rings Technical Specifications Standard Inside Diameter Of O Ring XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX

30 Conductive Elastomers: O Rings Technical Specifications 30 Standard Inside Diameter Of O Ring XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX-1860

31 Conductive Elastomers: O Rings Technical Specifications Standard Inside Diameter Of O Ring XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX XXX-XXXX-2500 Standard Vulcanized Tube O Rings Material Material Code Silicone Nickel Graphite SNG Silicone Nickel Graphite Fire Retardant SNG-FR Fluorosilicone Nickel Graphite FNG Silicone Silver Aluminium SSA Silicone Silver Aluminium 65 Shore Blue SSA (65B) Fluorosilicone Silver Aluminium FSA Fluorosilicone Silver Aluminium 70 Shore FSA (70) Silicone Silver Copper SSC Fluorosilicone Silver Copper FSC Silicone Nickel SN Fluorosilicone Nickel FN Tube O/D Cross Sections 1.00mm 1.20mm 1.30mm 1.40mm 1.50mm 1.60mm 1.80mm 2.00mm 2.20mm 2.40mm 2.50mm 2.60mm 2.80mm 3.00mm 3.20mm 3.50mm 3.80mm 4.00mm 4.30mm 4.50mm 4.80mm 5.00mm Standard Tube Cross Sections Section Reference 1.20 X X X X X X X X X X X X X X X X X X X X X X X X Minimum Inside Diameter of O Ring 10mm 10mm 10mm 10mm 10mm 10mm 10mm 12mm 12mm 12mm 12mm 12mm 16mm 16mm 16mm 19mm 22mm 22mm 25mm 25mm 28mm 30mm 31

32 Conductive Elastomers: O Rings Technical Specifications 32 Standard Inside Diameter Of O Ring 3.50 X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X How to order Select the material from the list and insert the material code followed by the section reference and finally the inside diameter. (1302-XXX-XXXX-XXXX-XXXX) e.g SNG Silicone Nickel Graphite Hollow cross section 3.0mm O/D x 1.5mm I/D O Ring 50mm internal. Inside Diameter of O Ring XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX-0365

33 Conductive Elastomers: O Rings Technical Specifications Standard Inside Diameter Of O Ring XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX

34 Conductive Elastomers: O Rings Technical Specifications 34 Standard Inside Diameter Of O Ring XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX-1790

35 Conductive Elastomers: O Rings Technical Specifications Standard Inside Diameter Of O Ring XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX XXX-XXXX-XXXX

36 Conductive Elastomers: Sheet & Flat Gaskets Product Overview Flat gaskets are produced from moulded sheet using economic rule dies. Larger gaskets can be cut from moulded or fabricated picture frames. This option has the advantage of saving material and allows larger gaskets to be produced economically. Fabricated frames use either extruded or moulded flat section that is joined by vulcanizing the polymer. The same conductive polymer compound is used to vulcanize the joints ensuring complete electrical conductivity is maintained across the joint. This process has allowed Kemtron to produce gaskets up to 2 meters long, with the same mechanical and electrical integrity as is found in a single part gasket cut from sheet. This method of manufacture often offers cost savings over cutting from sheet with subsequent loss of waste material. Our in-house production facilities are suitable for prototype, short and medium production runs, up to commercial quantities. Design Considerations It is important that this material is not overcompressed. If the design of the equipment does not allow for any mechanical method of preventing overcompression, the gasket should be fitted with built-in compression limiters, either metal stops fitted to the gasket, or metal collars fitted into each fixing hole. The material is not suitable in sliding applications. Recommended compression: 10% to 20%. Self adhesive backing (conductive or non-conductive) is offered as an assembly aid only. Fluorosilicone: self-adhesive backing is not recommended for use with this type of elastomer. Minimum material width should not be less than 2mm or at least the material thickness in any part of the gasket. If this cannot be achieved around fixing holes consider using a slot. Particular attention is required if specifying compression collars in holes. Consideration must be given to compression forces, hole centres, size and number of fixings and rigidity of mating flanges. Integral compression stops or collars should be considered to limit over compression if external controls cannot be applied. Recommended minimum sheet thickness for integral limits is 1.5mm. 36

37 Conductive Elastomers: Sheet & Flat Gaskets Technical Specifications Materials Material Code SNG FNG SNG-FR SSA FSA FSA(70) SSA (65B) SSC FSC SN FN Material Silicone Nickel Graphite Fluorosilicone Nickel Graphite Silicone Nickel Graphite Flame Retardant UL94 VO Silicone Silver Aluminium 60 Shore A Fluorosilicone Silver Aluminium 60 Shore A Fluorosilicone Silver plated Aluminium 70 Shore A Silicone Silver Aluminium 65 Shore A Blue Silicone Silver Copper Fluorosilicone Silver Copper Silicone Nickel Fluorosilicone Nickel Minimum Land Horse Shoe Slot 2mm Land area (Or thickness of material if over 2mm) Standard Sheet Sizes 150mm x 150mm (code 1210) 250mm x 300mm (code 1211) 300mm x 300mm (code 1212) Horseshoe slot Standard Thicknesses 0.5mm 0.8mm 1.0mm 1.2mm 1.5mm 1.6mm 1.8mm 2.0mm 2.5mm 3.0mm 3.2mm Other thicknesses and sheet sizes are available subject to minimum quantities. Insufficient Land How To Order Specify the sheet size code followed by the material code and finally the thickness using 4 numerical digits to 1 decimal place. If self adhesive backing is required ad after the part number CSAB for conductive, SAB for non conductive. Examples 1210-FNG-0008 = Fluorosilicone Nickel Graphite 150mm x 150mm x 0.8mm 1211-SSA-0015 SAB = Silicone Silver Aluminium self adhesive backed 250mm x 300mm x 1.5mm For die cut gaskets please supply a detailed drawing. Self Adhesive Backing Conductive elastomer sheets can be supplied with a conductive or non conductive adhesive. This adhesive has a shelf life of 6 months and is intended as an assembly aid only. Dimensional Tolerances: Thickness ± 0.15mm up to 2mm, ± 0.25mm above 2mm Linear ±0.8mm, Hole Centre s ± 0.4mm 37

38 Conductive Elastomers: Sheet & Flat Gaskets Technical Specifications (Continued) Surface Mounted Gaskets With surface mounted elastomeric gaskets, the aim should be to limit the compression of the gasket to between 10% and 20%. 10% being the minimum with a solid silicone style of gasket. (Some form of compression stop or limit is essential with surface mounted gaskets to prevent over compression). Compression stops can be built into many styles of gasket, or made as an integral part of the flange. Their height should equal that of the maximum compressed height of the gasket. Compression stops fitted into gaskets can be in the form of collars or washers so that fixing bolts can pass through them or as solid studs located either side of a fixing bolt. The thickness of the gasket for a known application can be calculated as follows e.g. Consider a gasket which can be compressed between 10% and 25% to be used on flanges which are not perfectly flat, i.e. the flanges without gaskets touch at some points and leave gaps in others. Since the gasket will compress between 10% and 25% we will require 25% compression at the high points and 10% at the low points (the gaps ). The greatest gap is therefore 15% of the gasket thickness. If that gap is 0.45mm, then a gasket of 3.0mm thickness is required This is fine in theory provided that the flanges do not bow when placed under load. To overcome flange distortion, fixings may need to be added, the number of which will be determined by the flange stiffness/rigidity. Compression 3 Compression Limit Applications Limit Collars 10mm 10mm Limit Stops Min Dia 3mm 38 Notice Information supplied in these data sheets is based on independent and laboratory tests which Kemtron believes to be reliable. Kemtron has no control over the design of customer s product which incorporates Kemtron s products, therefore it is the responsibility of the user to determine the suitability for his particular application and we recommend that the user make his own test to determine suitability. The product described in this data sheet shall be of standard quality, however the products are sold without warranty of fitness for a particular purpose, either expressed or implied, except to the extent expressly stated on Kemtron s invoice, quotation or order acknowledgement. Kemtron does not warrant that products described in this data sheet will be free of conflict with existing or future patents of third parties. All risks of lack of fitness, patent infringement and the like are assumed by the user.

39 Form-in-Place Gaskets Product Overview Kemtron Form-in-Place (FIP) Elastomer compounds are directly dispensed onto component hardware or enclosure via a pressurised fluid dispensing system on a numerically controlled XYZ table to form a gasket for RFI/EMI shielding and/or environmental seal for dust and moisture. The dispensing machine deposits the gasket by following a pre-determined CNC path to provide accuracy and repeatability. The process advantages are Component is integrated with EMI shielding and/ or environmental gasket. Materials are one-component room curable. Assembly time is reduced as gasket is included on component. Rapid prototyping. Low setup costs. Smaller gasket land required. Variety of materials available to optimise shielding and galvanic compatibility. No material waste. Excellent EMI shielding. Can be applied to metal and plastic components. 39

40 Form-in-Place Gaskets Product Overview (Continued) Applications Suited to applications where small, intricate gasket pro les are required such as on multi-compartment labyrinth housings with minimum gasket land area where traditional larger types of gasket are not suitable. This process also negates the assembly costs associated with traditional gaskets as the Form-in-Place gasket becomes an integral part of the housing or enclosure. The process is suitable for depositing on both metal and metallised plastic components/housing. Availability Kemtron can dispense FIP gaskets directly onto the customer s free issue hardware or can procure the component hardware thereby reducing the customer s supply base. Kemtron can also supply FIP compounds in syringes or Semco cartridges for the customer s own use. Form- in-place gasket materials include: For RFI/EMI Shielding Silver plated copper lled silicone. Silver plated aluminium lled silicone. Silver plated nickel lled silicone. Nickel coated graphite lled silicone. For Environmental Sealing only n lled silicone. Design Considerations o achieve optimum EMI shielding performance the component surface on which the gasket is to be deposited must be highly conductive as low contact resistance is required between the two. Chromate finishes on aluminium must be conductive. he gasket height can be speci ed between. mm to 2.0mm, gasket width will typically be 1.5x the gasket height. General tolerance is +/-0.1mm. Recommended gasket compression is between and. ver-compression can damage the gasket and as compression stops cannot be incorporated into the gasket they should be designed into the component hardware. asket path for the deposition can be determined from a sample part drawings or CA les. Production Capability o meet the varying demands of customer requirements Kemtron has developed its own CNC Form-in-Place dispenser. FIP gasketing work has become a regular feature of our production work and we are able to provide a reliable accurate and quick response to even high volume orders. 40 Notice Information supplied in these data sheets is based on independent and laboratory tests which Kemtron believes to be reliable. Kemtron has no control over the design of customer s product which incorporates Kemtron s products, therefore it is the responsibility of the user to determine the suitability for his particular application and we recommend that the user make his own test to determine suitability. he product described in this data sheet shall be of standard quality however the products are sold without warranty of fitness for a particular purpose, either expressed or implied, except to the extent expressly stated on emtron s invoice quotation or order acknowledgement. Kemtron does not warrant that products described in this data sheet will be free of conflict with existing or future patents of third parties. All risks of lack of tness patent infringement and the like are assumed by the user.

41 Form-in-Place Gaskets Technical Specification Materials Silver plated Copper Particles in Silicone Elastomer FIPSSC Silver plated Aluminium Particles in Silicone Elastomer FIPSSA Density 3.3 g/cm -3 ardness Shore A Volume resistivity. Ω.cm Adhesion N cm -2 Attenuation M to MIL-S dB (typically) Compression recommended (allowable range) asket resistance. Ω.cm -1 Elongation Compression set hours at C Service temperature range - C to C orce de ection. mm high gasket section. N cm N/cm N/cm -1 Density 2.0 g/cm -3 ardness Shore A Volume resistivity. Ω.cm Adhesion N cm -2 Attenuation M to MIL-S dB (typically) Compression recommended (allowable range) asket resistance. Ω.cm -1 Elongation Compression set hours at C Service temperature range - C to C orce de ection. mm high gasket section. N cm N/cm N/cm -1 Nickel plated Graphite Particles in Silicone Elastomer FIPSNG Silver plated Nickel Particles in Silicone Elastomer FIPSSN Density 2.5 g/cm -3 Hardness 50 Shore Volume resistivity. Ω.cm Adhesion N cm -2 Attenuation M to MIL-S dB (typically) Compression recommended (allowable range) asket resistance. Ω.cm -1 Elongation Compression set hours at C Service temperature range - C to C orce de ection. mm high gasket section. N cm N/cm N/cm -1 Density 3.6 g/cm -3 ardness Shore A Volume resistivity. Ω.cm Adhesion N cm -2 Attenuation M to MIL-S dB (typically) Compression recommended (allowable range) asket resistance. Ω.cm -1 Elongation Compression set hours at C Service temperature range - C to C Force/deflection 0.7mm high gasket section 1.7 N/cm N/cm N/cm -1 Typical Form-in-Place Deposits 41

42 Conductive Adhesives Product Overview Kembond is a range of electrically conductive adhesives that provide a variety of RFI/EMI shielding and grounding solutions. They consist of a densely loaded adhesive filled with micro sized highly conductive particles. Application Vibration and or shock resistant sealant adhesive for electronic assemblies. Electrical connection bonding of materials with dissimilar thermal expansion coefficients i.e. mounting shielded windows EMI shielding with environmental sealing (IP68 possible). ES control grounding. Structural adhesive can be used to permanently bond metal assemblies. Electrical connection of components avoiding the use of mechanical fixings or solder. Storage It is recommended that when not in use that the material is stored in a cool dark, dry place. If kept properly sealed and in a suitable location then the material will remain usable for up to 3 months, depending on type. Handling When using this material observe usual standards of industrial hygiene/practice. Avoid skin/eye contact and work in a well ventilated area. For more detailed information please refer to the MSDS (Material Safety Data Sheet). 42

43 Conductive Adhesives Product Overview (Continued) Availability Electrically Conductive Silicone Adhesives RTV Single component ready to use. Room temperature cure. Neutral cure does not involve corrosive by-products on curing. Safe for use with most common substrates non tarnishing / discolouring. Excellent resistance to ageing. ide service temperature range remains exible and conductive at extremes of temperature. Stable low bond oint resistance through temperature cycling. embond R V can be supplied in either standard manual or pneumatic (air dispense) 10ml syringe barrels from which the material may be directly applied. Both formats will accept a variety of dispense tips (including luer lock types) for accurate, controlled application. Larger sizes of 55ml, 170ml & 310ml are available on request. Electrically Conductive Epoxy Adhesives Very high bond strength. Room temperature cure. lexible degree is variable by ad usting mix ratio. Extremely resistant to fracture. Safe for use with most common substrates non tarnishing / discolouring. Excellent resistance to ageing. ide service temperature range retains strength and conductivity at extremes of temperature. Stable low bond oint resistance through temperature cycling. embond Epoxy can be supplied in either ml or ml double syringe packs. The material is automatically dispensed in the correct 50:50 ratio. Alternatively, this material can be supplied in separate syringe barrels where variable mix ratios are to be used. The adhesive mix ratio for epoxy may be varied in order to modify the cured properties. For most applications we would recommend a 50:50 mix ratio that will result in a cured adhesive with a small degree of exibility high strength and reasonably good low temperature performance. Increasing the proportion of hardener up to around a maximum of 125:50 will result in a cured adhesive with a relatively high degree of exibility along with improved low temperature performance but other physical properties will be reduced. Ensure the two components are thoroughly mixed. Once mixed this material has a working (or pot) life of approximately one hour (depending on the ambient temperature) and may be transferred to a syringe for precise application if required. Assemble parts as soon as possible and certainly within minutes of adhesive application. In most cases parts may be handled after 12 hours but avoid stressing the oint until full cure has been achieved. Cure rate may be controlled by means of temperature. The adhesive will fully cure within 3 hours at 60 C. If curing at elevated temperatures be careful to avoid excessive adhesive out ow due to the uncured adhesive viscosity reducing during the curing process. Excess material should be removed by means of a spatula or similar implement. Smaller traces of the uncured material may be removed by wiping with a lint free cloth damped with methylated spirit, isopropyl alcohol or MEK taking care to observe the safety precautions required in using ammable harmful solvents of this type. A priming agent is available for treating some inconsistent or difficult to bond surfaces. Please contact us for further information. Design considerations Service conditions. Compatibility with substrate. alvanic compatibility. Rigid or exible bond. Instructions for Use Surfaces should be clean dry and sound i.e. free from loose material. It is recommended that areas to be bonded are cleaned using a suitable solvent prior to applying the sealant. To ensure the highest level of electrical or shielding performance it is essential that the surfaces to be bonded have a low contact resistance. This means that materials that have a naturally occurring oxide layer such as aluminium alloys may need to be lightly abraded and cleaned directly prior to bonding. Notice Information supplied in these data sheets is based on independent and laboratory tests which Kemtron believes to be reliable. Kemtron has no control over the design of customer s product which incorporates Kemtron s products, therefore it is the responsibility of the user to determine the suitability for his particular application and we recommend that the user make his own test to determine suitability. The product described in this data sheet shall be of standard quality, however the products are sold without warranty of fitness for a particular purpose, either expressed or implied, except to the extent expressly stated on Kemtron s invoice, quotation or order acknowledgement. Kemtron does not warrant that products described in this data sheet will be free of con ict with existing or future patents of third parties. All risks of lack of fitness, patent infringement and the like are assumed by the user. 43

44 Conductive Adhesives Technical Specification Silver loaded epoxy adhesive Silver Aluminium loaded RTV silicone Kembond Epoxy SE-002 Kembond SSA-RTV Uncured Properties Uncured properties Colour Silver Colour Light Tan Form Semi viscous paste orm Semi owable paste Cure time at 23 C / 50% RH 24 hours Cure time 10mm bond width at 23 C / 50% RH 24 hours Recommended minimum time before stressing bond 48 hours Recommended minimum time before stressing bond 48 hours Cured Properties Cured Properties Density 3.0 g/cm³ Density 2.1 g/cm³ Adhesion lap shear aluminium to aluminium N cm Hardness 65 Shore A Service temperature range -50 C to 200 C Adhesion lap shear aluminium to aluminium N cm Bond resistance (aluminium to aluminium) Thermal conductivity <10mΩ cm 4.8 Wm/K Compression recommended (allowable range)25% (10-50%) Service temperature range -50 C to 125 C Recommended bond thickness 0.25mm Bond resistance (aluminium to aluminium) <20mΩ cm Thermal conductivity 0.8 Wm/K Silver copper loaded RTV silicone Recommended bond thickness mm Kembond SSC-RTV Uncured properties Colour orm Cure time 10mm bond width at 23 C / 50% RH Recommended minimum time before stressing bond Tan Semi owable paste 24 hours 48 hours Nickel Graphite loaded RTV silicone Kembond SNG-RTV Uncured properties Colour Dark grey orm Semi owable paste Cured Properties Density 3.3 g/cm³ Cure time 10mm bond width at 23 C / 50% RH Recommended minimum time before stressing bond 24 hours 48 hours Hardness 65 Shore A Adhesion lap shear aluminium to aluminium N cm Compression recommended (allowable range)25% (10-50%) Service temperature range -50 C to 125 C Bond resistance (aluminium to aluminium) <10mΩ cm Thermal conductivity 1.0 Wm/K Recommended bond thickness mm Cured Properties Density 2.1 g/cm³ Hardness 75 Shore A Adhesion lap shear aluminium to aluminium N cm Service temperature range -50 C to 150 C Bond resistance (aluminium to aluminium) <10mΩ cm Thermal conductivity 1.0 Wm/K Recommended bond thickness mm Ordering Information embond SN R V- cc Silicone R V loaded with Nickel graphite particules in 310cc cartridge. 44

45 Oriented Wires in Silicone & Fluorosilicone Rubber Product Overview A flat, sheet material, comprising a solid silicone rubber, embedded with Monel or Aluminium metal wires orientated perpendicular to its surface. Excellent RFI/EMI/EMP shielding performance is achieved as the material has a wire density of up to 140 wires / cm 2 in solid silicone providing an environmental and RFI/ EMI seal when clamped between two metallic surfaces. These wires are crimped to aid compression and are chemically bonded to ensure their retention. They will also penetrate most light oxide layers, ensuring a low contact resistance path when suitably compressed. A choice of silicones variants along with different wire counts are available allowing this product to be used in a wide range of applications. Kemtron have developed new grades of material to fulfil a need that meets the performance of our 430/440 materials but with improved environmental sealing qualities. We have achieved this by using a very soft solid silicone with a reduced wire count of 100 wires per cm 2 the same as our silicone sponge. The advantages of these new materials over silicone sponge are that we can manufacture increased sheet widths of 225mm with a minimum thickness of 0.8mm. Material consistency is a great advantage over silicone sponge as there is no uneven cell structure to consider that affects moisture ingress and closure force (Full data on these materials can be found listed under 470/480 in the Technical Specification). 45

46 Oriented Wires in Silicone & Fluorosilicone Rubber Product Overview (Continued) 46 Application A good solution for achieving RFI/EMI/EMP and environmental sealing in a single gasket. Ideal for use as access panels, seals, connector gaskets etc. Good conformity to allow for uneven surfaces. Availability Kemtron is able to offer a wide variety of options as the material is cut in-house from large blocks, up to 225mm wide, using our high-speed slicer, enabling us to offer all thicknesses (subject to material type) to suit the customer s exact design requirement. Die- cut gaskets. Large fabricated gaskets. Virtually any flat shape can be produced. Sheet material. Strip material available in continuous lengths. Self-adhesive backing to allow for easy assembly. Can be fitted with compression limit stops or collars. Small gaskets can be punched in one operation, keeping production costs to a minimum. Larger gaskets can be produced cost effectively and without the constraint of sheet size limitation from strips of material fabricated into the required finished shape, thus avoiding waste material from the centre of the gasket. A fluorosilicone version is available for use in environments where fuels / oils / hydraulic fluids and other contaminants are present. Solid Silicone 410/420, for use in applications where higher compression forces allow for better environmental sealing. Soft solid silicone 470/480 or silicone sponge 430/440 for applications that require lower compression forces. Design Considerations It is important that this material is not overcompressed. If the design of the equipment does not allow for any mechanical method of preventing over-compression, the gasket should be fitted with built-in compression limiters, either metal stops fitted to the gasket, or metal collars fitted around each fixing hole. There is no need for a conductive connection where strips are joined as the wires forming the EMC contact run vertically though the material; a waterproof seal is achieved by vulcanising the join with silicone. The material is not suitable for frequent opening or sliding applications. Recommended compression: Solid 15% to 20%, Sponge 15% to 25%. Fluorosilicone: self-adhesive backing is not recommended for use with this type of elastomer. Minimum material width should not be less than 2mm or at least the material thickness in any part of the gasket. If this cannot be achieved around fixing holes consider using a slot. Particular attention is required if specifying compression collars in holes. Particular consideration must be given to compression forces (see data in this section) hole centres, size and number of fixings and rigidity of mating flanges. Compression Limit Application Production Capabilities Kemtron holds large stocks of raw material blocks, which are cut in-house on one of the most advanced slicing machines in Europe, and which enables us to produce bespoke gaskets economically and on time. We are able to cut sheets up to 228mm wide by 900mm long, whilst holding a parallel tolerance of +/-0.2mm and can apply self-adhesive backing prior to die cutting and or fabrication. Gasket fabrication is a routine feature of our work, enabling us to produce economic gaskets by maximising material usage, without the limitations of sheet width. Joins are vulcanised using a silicone compound and overcompression stops or collars can be fitted to the gasket if required. Our in-house production facilities are suitable for prototype, short and medium production runs, up to commercial quantities. Minimum Land Horse Shoe Slot Limit collars Limit stops min dia 3mm 10mm Insufficient land 10mm 2mm Land area (or thickness of material if over 2mm) Horseshoe slot

47 Oriented Wires in Silicone & Fluorosilicone Rubber Technical Specification Typical Shielding Performance Frequency 410/ / / /480 20Mhz Mhz Mhz Mhz Mhz Mhz Mhz Mhz Mhz Ghz Ghz Ghz Ghz Ghz Ghz Typical Closing Force Required Code Material Thickness Compression % N/cm 2 410/ % 45 15% 60 20% 90 25% % 60 15% 85 20% % % 80 15% % % % 90 15% % % 170 Typical Closing Force Required Code Material Thickness Compression % N/cm 2 430/ % 50 Typical Closing Force Required 15% 50 20% 55 25% % 50 15% 50 20% 50 25% % 40 15% 40 20% 40 25% 45 Code Material Thickness Compression % N/cm 2 470/ % 25 15% 40 20% 45 25% % 37 15% 39 20% 41 25% % 27 15% 32 20% 36 25% 40 The above data is representative of results from tests and show forces that you should expect to experience. When using these figures you should allow for tolerances in the gasket material and also on the hardware. These figures are given as a guide only. Notice Information supplied in these data sheets is based on independent and laboratory tests which Kemtron believes to be reliable. Kemtron has no control over the design of customer s product which incorporates Kemtron s products, therefore it is the responsibility of the user to determine the suitability for his particular application and we recommend that the user make his own test to determine suitability. The product described in this data sheet shall be of standard quality, however the products are sold without warranty of fitness for a particular purpose, either expressed or implied, except to the extent expressly stated on Kemtron s invoice, quotation or order acknowledgement. Kemtron does not warrant that products described in this data sheet will be free of conflict with existing or future patents of third parties. All risks of lack of fitness, patent infringement and the like are assumed by the user. 47

48 Oriented Wires in Silicone & Fluorosilicone Rubber Technical Specifications (Continued) Dimensional Tolerances Linear +/- 0.8mm, Hole Centres +/- 0.4mm Thickness +/- 0.13mm Handling Considerations Care should be taken when handling this material as any exposed metal points may scratch unprotected skin Material Types and Sizes Part No. Material Type Min thickness Sheet width(s) Max sheet length 410 Monel wires in 0.8mm 225mm 1000mm Solid Silicone 420 Aluminium wires 0.8mm 225mm 900mm in Solid Silicone 430 Monel wires in 1.2mm 114mm 900mm Silicone Sponge 440 Aluminium wires 1.2mm 114mm 900mm in Silicone Sponge 450 Monel wires in 0.8mm 150mm 900mm Solid Fluorosilicone 460 Aluminium wires in 0.8mm 150mm 900mm Solid Fluorosilicone 470 Monel wires in Soft 0.8mm 225mm 1000mm Solid Silicone 480 Aluminium wires in Soft 0.8mm 225mm 1000mm Solid Silicone Available in a Range of Widths To order strips use the material type number followed by the thickness and width (expressed as 4 digits to one decimal place). Add SAB to the end of the part number if you require self-adhesive backing. Example Part number 1.6mm thick Monel Wires in Silicone Sponge, width 12.7mm 0.8mm thick Aluminium Wires in SAB Solid Silicone, width 3.2mm with self-adhesive backing Standard Strip Material 410: Monel Wire in Solid Silicone 420: Aluminium Wire in Solid Silicone 430: Monel Wire in Silicone Sponge 440: Aluminium Wire in Silicone Sponge 450: Monel in Solid Fluorosilicone 460: Aluminium in Solid Fluorosilicone 470: Monel wire in soft solid silicone 480: Aluminium wire in soft solid silicone Material Code Ht. Width Part Number * * * * * * * * * * *Not available in 0.8mm thick. Material Specifications Wire Monel BS 3075 NA13 QQ-N-281-B Aluminium BS EN 537 pt 3 Alloy 5056 Elastomers Specifications Temperature Range Colour Silicone Solid ZZ-R-765 2b -60ºC TO 200ºC Light Grey Soft Silicone Solid ZZ-R-765 2b -60ºC TO 200ºC Light Grey Silicone Sponge AMS ºC TO 200ºC Light Grey Flourosilicone Mil-R G 50-55ºC TO 200ºC Blue Test Standard Solid Silicone Tensile strength ASTM D MPa Elongation ASTM D % 48

49 Woven & Expanded Wire in Elastomers Product Overview A composite of metal wire mesh impregnated with an elastomer, creating a highly conductive and resilient gasketing material for EMI/RFI shielding and environmental sealing applications. Choose from: oven aluminium wire expanded aluminium or expanded Monel sheet impregnated with an elastomer filler Silicone, fluorosilicone or synthetic rubber or; Expanded Monel sheet without elastomer ller. The conductive metallic surfaces of the material provide an excellent low resistance contact whilst under the correctly designed conditions the rubber component ensures effective dust and moisture sealing. The exposed metallic points on the woven product, where the weave of the wire overlaps, create approximately 80 contacts per cm 2 whilst the raised edge on the expanded sheet product creates approximately 20 contacts per cm 2. Applications Provides an economic approach to gasketing flat surfaces where unevenness does not exceed 0.10mm and/or where material thickness constraints occur. Particularly suited to small thin gaskets such as MIL type connectors etc. Other thin gaskets can be made in-house using specialist cutting methods and the material can also be supplied as continuous sheet for customer s own production purposes. Fluorosilicone versions are suitable for applications where fuels/oils/hydraulic fluids and other contaminants are present. Availability Can be supplied as Continuous roll mm wide in. mm and. mm thickness (see specification). Standard connectors. espoke gaskets made to customer s speci cation. 49

50 Woven & Expanded Wire in Elastomers Product Overview (Continued) Design Considerations hese materials are not suitable for oining or fabricating. Gaskets are only available as a single part. asket si e is limited to mm in width with minimal constraints on length. Minimum material width should not be less than 2.5mm in any part of the gasket. If this cannot be achieved around fixing holes, consider using a slot. As these materials are of a solid nature they give very little compression and should therefore be used between ridged flat surfaces with a combined flatness tolerance of 0.1mm maximum. Compression limiting stops are therefore not normally required with these materials. Self-adhesive backing is not recommended. Production Capability Kemtron holds large stocks of raw materials which, together with our in-house facilities using precision laser cut rule dies, enables us to produce bespoke gaskets economically and on time, whether for prototype, short and medium production runs or for commercial quantities. Minimum Land 2.5mm Land area (Or thickness of material if over 2mm) Horse Shoe Slot Horseshoe slot Insufficient Land 50 Notice Information supplied in these data sheets is based on independent and laboratory tests which Kemtron believes to be reliable. Kemtron has no control over the design of customer s product which incorporates Kemtron s products, therefore it is the responsibility of the user to determine the suitability for his particular application and we recommend that the user make his own test to determine suitability. The product described in this data sheet shall be of standard quality, however the products are sold without warranty of fitness for a particular purpose, either expressed or implied, except to the extent expressly stated on Kemtron s invoice, quotation or order acknowledgement. Kemtron does not warrant that products described in this data sheet will be free of conflict with existing or future patents of third parties. All risks of lack of fitness, patent infringement and the like are assumed by the user.

51 Woven & Expanded Wire in Elastomers Technical Specification Typical Shielding Performance 200KHz 100MHz 1GHz EMP Survive Expanded Monel (unfilled) 530/560 60dB 90dB 70dB Yes Woven Aluminium (silicones) 525/525F 65dB 90dB 75dB Yes Tolerances Hole centres +/- 0.4mm Length +/- 0.8mm Thickness ± 0.13mm Material Specifications Wire Expanded Monel QQ-N-281B Expanded Aluminium QQ-A-250 Woven Aluminium AMS 4182 Elastomers Specification Temperature Range Colour Silicone ZZ-R-765 Class2 GR50-60ºC TO 200ºC Grey Fluorosilicone MIL-R ºC TO 200ºC Blue Synthetic AMS 3222C -40ºC TO 125ºC Black Handling considerations Care should be taken when handling this material as any exposed metal points may scratch unprotected skin. Specifications Part Number Material Type Thickness Sheet width 515 Woven Aluminium in Synthetic 0.5mm 305mm 525 Woven Aluminium in Silicone 0.5mm 305mm 525F Woven Aluminium in Fluorosilicone 0.5mm 305mm 565 Expanded Monel in Silicone 0.5mm 305mm 535 Expanded Monel in Silicone 0.8mm 305mm 560 Expanded Monel Unfilled 0.5mm 305mm 530 Expanded Monel Unfilled 0.8mm 305mm 555 Expanded Aluminium in Silicone 0.5mm 305mm 545 Expanded Aluminium in Silicone 0.8mm 305mm 51

52 Knitted Wire Mesh Overview A range of knitted wire mesh gaskets, providing a cost-effective solution to high shielding performance applications in the magnetic and electrical fields RFI/EMI and including EMP. Manufactured on a circular wire knitting machine using a single wire. The mono-filament interlocking-loop construction gives strength while allowing it to conform to almost any size or shape. The manufacturing process allows for an optional elastomer core to be included in to the product to aid compression. An additional environmental seal/carrier is also an option. It is available in a variety of combinations to suit many EMC and environmental sealing applications. Kemtron s knitted wire mesh is available in 3 options 1. Solid Knitted Wire Mesh. 2. Elastomer cored knitted wire mesh. 3. Knitted wire mesh with an additional environmental seal. Production Capabilities Kemtron has developed its knitted wire mesh production facility and expertise in this area to enable it to produce RFI/EMI gaskets in a wide range of materials and in many different size configurations. Together with our extensive fabrication capabilities and large stocks of raw materials, we can manufacture knitted wire mesh gaskets to suit many applications. We offer a bespoke service, which can also produce economical gaskets, with good delivery times, in prototype quantities or for short, medium or large commercial production runs. 52 Summary Solid Knitted Elastomer Cored Knitted Wire Mesh with an Wire Mesh Knitted Wire Mesh Additional Environmental seal RFI/EMI/EMC shield EMP survivability Environmental seal Dust only Dust only Frequent opening Continuous lengths Cut to length Fabricated gasket Mesh over elastomer core Silicone/neoprene carrier Compression stops /collars

53 Knitted Wire Mesh Solid Knitted Wire Mesh Product Overview The product consists of a knitted wire that is formed into an all wire profile forming a continuous gasket strip. Application Solid knitted mesh gaskets provide an excellent EMI/RFI/EMP gasket shield between two metallic surfaces and with the choice of wire mesh material available allows for a good galvanic match with mating flanges, thereby limiting the possibility of corrosion between gasket and flange. RFI/EMI/EMP applications. Panel seals in screened rooms. Areas with infrequent access. Cable Shielding (Wrapping with flat bandage). Availability In continuous lengths, cut to length or fabricated into finished gaskets by spot welding and stitching to suit customer requirements. Variety of profiles and sizes available. Fabricated gaskets. Compressed mesh rings. Self adhesive backing is not recommended with this version of mesh. Design Considerations Consideration should be given to the termination of cut mesh ends. Sometimes loose wires are evident after cutting. Kemtron are experts at mesh termination however if you choose to cut the mesh yourself loose wires can be avoided by: Dipping the end in glue, Spot welding the cut end. Sewing the cut mesh end. Compression forces required to achieve good contact. Also the rigidity of the host metalwork. Galvanic compatibility. Select from a choice of wire. Water and moisture sealing is not possible with this product. However it does offer a limited dust seal. Solid knitted wire mesh suffers from compression set. So it is not recommended for frequent opening of panels. 53

54 Knitted Wire Mesh Solid Knitted Wire Mesh Technical Specifications Typical Shielding Performance H Field MHz Monel >104 TCS >104 S/St Aluminium >104 Flat Bandage Note: This product is approx 0.5mm thick. E Field MHz Monel >118 >136 > TCS >118 >136 > S/St Aluminium >118 >136 > Profile P Field MHz ,000 Monel TCS S/St Aluminium Material Code Materials Monel Alloy 400 Wire (Mon) Wire diameter 0.11mm. UK Specification to BS3075 NA13 USA Specification to AMS 4730 Tin Plated Copper Clad Steel (TCS) Wire diameter 0.11mm UK Specification BS2316*, BS4087* USA Specification ASTM B277*, ASTM B452*, ASTM B520, ASTM B33*, AISI 1010 * There is no complete specification for this material. Processes have been derived from parts of the above where applicable. Stainless Steel (S/St) UK Specification BS EN S19 Wire diameter 0.11mm Aluminum (Alu) Specification BS EN 537 pt 3 Wire diameter 0.13mm Tolerances Round and rectangular sections +/-0.8mm Fin Dimensions +/- 1.5mm Mon TCS S/St Alu Width Part Number Other sizes are available on request How To Order The sizes shown on the tables are typical examples of our range other sizes are available on request. To make a part number, use the wire material code from the material code box followed by the part number. Part No i.e round section monel wire 3.2mm diameter 54

55 Knitted Wire Mesh Solid Knitted Wire Mesh Technical Specifications (Continued) Round Rectangular Profile Profile Material Code Mon TCS S/St Alu Diameter Part Number Other sizes are available on request Material Code Mon TCS S/St Alu Height Width Part Number Other sizes are available on request 55

56 Knitted Wire Mesh Solid Knitted Wire Mesh Technical Specifications (Continued) Round with Fin Twin Round with Fin Profile Profile Material Code Mon TCS S/St Alu Dia Fin W Part Number Material Code Mon TCS S/St Alu Dia Width Part Number Other sizes are available on request Other sizes are available on request 56

57 Knitted Wire Mesh Over an Elastomer Core Product Overview This product is a knitted wire mesh over an elastomer core such as neoprene or silicone cellular profile or tube. Usually this consists of 2 layers of knitting over the elastomer core but small sections 1.5mm diameter requiring only 1 layer. The knitted mesh is then formed into the selected profile making a continuous gasket strip which is flexible and compressible and which makes an excellent RFI/EMI/EMP gasket. Application In addition to making an excellent EMI/RFI/EMP shield between two metallic surfaces the choice of wire mesh material available also allows for a good galvanic match with mating flanges, thereby limiting the possibility of corrosion between gasket and flange. Further, the elastomer core of the gasket allows it to be compressed using low to medium force conforming to uneven surfaces and recovering well after use. Groove gaskets such as O rings. Due to its resiliency and low compression force, ideal for use in situations where repeated opening and closing operations are necessary. Availability In continuous lengths. Cut to length. Fabricated into finished gaskets. Variety of profiles and sizes. Fabricated gaskets. Selection of wire to meet galvanic compatibility requirements. Large selection of elastomer cores are available to meet conditions such as temperature range, compression set, compression force. Although round or rectangular cross sections are the most commonly used, other sections can be made to custom designs. Where EMP protection is needed, a minimum of 7 layers is recommended. Additional layers can also be added depending on the application of the equipment and degree of shielding required. Self adhesive backing is not recommended with this version of mesh. Design Considerations Consideration should be given to the termination of cut mesh ends. Sometimes loose wires are evident after cutting. Kemtron are experts at mesh termination however if you choose to cut the mesh yourself loose wires can be avoided by: Dipping the end in glue, Spot welding the cut end. Sewing the cut mesh end. Compression forces required to allow good contact. Also the rigidity of the host metalwork. Galvanic compatibility. Select from a choice or wire. Water and moisture sealing is not possible with this product. However, it does offer a limited dust seal. 57

58 Knitted Wire Mesh Over an Elastomer Core Technical Specifications Typical Shielding Performance H Field MHz Monel >104 TCS >104 S/St E Field MHz Monel >118 >136 > TCS >118 >136 > S/St How To Order The sizes shown on the tables are typical examples of our range other sizes are available on request. To make a part number, use the wire material code from the material code box followed by the part number. Part No i.e round section with 2 layers monel wire over 3.2mm diameter silicone sponge Round Neoprene Sponge Core P Field MHz ,000 Monel TCS S/St Materials Monel Alloy 400 Wire Wire diameter 0.11mm. UK Specification to BS3075 NA13 USA Specification to AMS 4730 Tin Plated Copper Clad Steel (TCS) Wire diameter 0.11mm UK Specification BS2316*, BS4087* USA Specification ASTM B277*, ASTM B452*, ASTM B520, ASTM B33*, AISI 1010 * There is no complete specification for this material. Processes have been derived from parts of the above where applicable. Stainless Steel (S/St) UK Specification BS EN S19 Wire diameter 0.11mm Aluminum (Alu) Specification BS EN 537 pt 3 Wire diameter 0.13mm Solid Silicone Rubber Generally meets ZZ-R-765 Temperature range -40 C to +200 C Service life >20 years Sponge Silicone Rubber USA Specification AMS 3195 Temperature range -40 C to +200 C Service life >20 years Sponge Neoprene Rubber USA Specification ASTM D1056 (84) SCE 42 Temperature range -15 C to +80 C Condition medium Tolerances on Rubbers Note: All sizes listed are that of the Elastomer core, Allowances must be made for the wire mesh 1 layer approximately 0.4mm and 2 layers 0.8mm Round and rectangular mesh sections +/-0.8mm Up to 2.0mm diameter or thickness ± 0.5mm 2.0mm to 10.0mm diameter or thickness ± 0.8mm Above 10mm diameter or thickness ± 1.5mm Profile Material Code Mon TCS S/St Alu Dia Other sizes are available on request Part Number

59 Knitted Wire Mesh Over an Elastomer Core Technical Specifications (Continued) Round Silicone Sponge Core Round Silicone Tube Core Profile Profile Material Code Mon TCS S/St Alu Dia Part Number Other sizes are available on request Material Code Mon TCS S/St Alu Dia Part Number Other sizes are available on request 59

60 Knitted Wire Mesh Over an Elastomer Core Technical Specifications (Continued) Rectangular Silicone Sponge Core Rectangular Neoprene Sponge Core Profile Profile Material Code Mon TCS S/St Alu Ht Width Part Number Other sizes are available on request Material Code Mon TCS S/St Alu Ht Width Part Number Other sizes are available on request 60

61 Knitted Wire Mesh Over an Elastomer Core Technical Specifications (Continued) Round with Fin Silicone Sponge Core Round with Fin Silicone Tube Core Profile Profile Material Code Mon TCS S/St Alu Dia Fin W Part Number Other sizes are available on request Material Code Mon TCS S/St Alu Dia Fin W Part Number Other sizes are available on request 61

62 Knitted Wire Mesh Over an Elastomer Core Technical Specifications (Continued) Twin Round with Fin Silicone Sponge Cores Twin Round with Fin Silicone Tube Cores Profile Profile Material Code Mon TCS S/St Alu Dia Width Part Number Other sizes are available on request Material Code Mon TCS S/St Alu Dia Width Part Number Other sizes are available on request 62

63 Knitted Wire Mesh with an Environmental Seal Product Overview Manufactured from either solid knitted wire mesh or knitted wire mesh over an elastomer core bonded to an elastomer environmental seal. Application This type of gasket is very suitable where a high level of shielding is required along with an environmental seal. Provides an economic approach to combination RFI/EMI/EMP and environmental sealing. Suitable for gaps with large tolerances. Door seals. Panel seals. Due to its resiliency and low compression force, ideal for use in situations where repeated opening and closing operations are necessary. Availability Continuous lengths up to 10 mtrs long. Fabricated gaskets to customer s drawings. Can be fitted with compression limit stops or collars. Easily assembled using the optional self adhesive backing. A broad range of sizes available. A large range of materials to suit many RFI/EMI/EMP and climatic conditions including NBC. Large fabricated gaskets can be produced economically. UL flame retardant approved materials are also available. Design Considerations It is important that this material is not over-compressed. If the design of the equipment does not allow for any mechanical method of preventing over-compression, the gasket should be fitted with built-in compression limiters, either metal stops fitted to the gasket, or metal collars fitted into each fixing hole. When specifying die cut gaskets minimum material width should not be less than 2mm or at least the material thickness in any part of the gasket. If this cannot be achieved around fixing holes consider using a slot. Particular attention is required if specifying compression collars in holes. Particular consideration must be given to compression forces hole centres, size and number of fixings and rigidity of mating flanges. Consideration should be given to the termination of cut mesh ends. Sometimes loose wires are evident after cutting. Kemtron are experts at mesh termination however if you choose to cut the mesh yourself loose wires can be avoided by: Dipping the end in glue. Spot welding the cut end. Sewing the cut mesh end. Galvanic compatibility. Select from a choice or wire. Horse Shoe Slot Minimum Land Horseshoe slot Insufficient land 2mm min land area (or thickness of material if over 2mm) 63

64 Knitted Wire Mesh with an Environmental Seal Technical Specifications Surface Mounted Gaskets With surface mounted elastomeric gaskets, the aim should be to limit the compression of the gasket to between 10% and 20%. 10% being the minimum with a solid silicone style of gasket. (Some form of compression stop or limit is essential with surface mounted gaskets to prevent over compression). Compression stops can be built into many styles of gasket, or made as an integral part of the flange. Their height should equal that of the maximum compressed height of the gasket. Compression stops fitted into gaskets can be in the form of collars or washers so that fixing bolts can pass through them or as solid studs located either side of a fixing bolt. The thickness of the gasket for a known application can be calculated as follows e.g. Consider a gasket which can be compressed between 10% and 25% to be used on flanges which are not perfectly flat, i.e. the flanges without gaskets touch at some points and leave gaps in others. Since the gasket will compress between 10% and 25% we will require 25% compression at the high points and 10% at the low points (the gaps ). The greatest gap is therefore 15% of the gasket thickness. If that gap is 0.45mm, then a gasket of 3.0mm thickness is required This is fine in theory provided that the flanges do not bow when placed under load. To overcome flange distortion, fixings may need to be added, the number of which will be determined by the flange stiffness/rigidity. Compression 3 Compression Limit Applications Limit Collars 10mm 10mm Limit Stops Min Dia 3mm 64

65 Knitted Wire Mesh with an Environmental Seal Technical Specifications (Continued) Typical Shielding Performance For 300 series as achieved by testing to MIL-STD 285 modified. H Field MHz Monel >104 TCS >104 S/St E Field MHz Monel >118 >136 > TCS >118 >136 > S/St P Field MHz ,000 Monel TCS S/St Materials Monel Alloy 400 Wire Wire diameter 0.11mm. UK Specification to BS3075 NA13 USA Specification to AMS 4730 Tin Plated Copper Clad Steel (TCS) Wire diameter 0.11mm UK Specification BS2316*, BS4087* USA Specification ASTM B277*, ASTM B452*, ASTM B520, ASTM B33*, AISI 1010 * There is no complete specification for this material. Processes have been derived from parts of the above where applicable. Stainless Steel (S/St) UK Specification BS EN S19 Wire diameter 0.11mm Aluminum (Alu) Specification BS EN 537 pt 3 Wire diameter 0.13mm Solid Silicone Rubber Generally meets ZZ-R-765 Temperature range -40 C to +200 C Service life >20 years Sponge Silicone Rubber USA Specification AMS 3195 Temperature range -40 C to +200 C Service life >20 years Sponge Neoprene Rubber USA Specification ASTM D1056 (84) SCE 42 Temperature range -15 C to +80 C Condition medium Tolerances Note: All sizes listed that have an Elastomer core are the Elastomer size, Allowances must be made for the wire mesh, 1 layer approximately 0.4mm and 2 layers 0.8mm Round and rectangular mesh sections +/-0.8mm Carrier size +/-0.8 Finished gaskets +/-0.8mm up to 300mm +/-1.2mm over 300mm Hole centres +/-0.4mm Tolerances on Rubbers Up to 2.0mm diameter or thickness ± 0.5mm 2.0mm to 10.0mm diameter or thickness ± 0.8mm Above 10mm diameter or thickness ± 1.5mm How To Order The sizes shown on the tables are typical examples of our range other sizes are available on request. To make a part number, use the wire material code from the material code box followed by the part number. Part No i.e : 3.2mm diameter silicone sponge core with 2 layers TCS wire mesh attached to silicone sponge carrier 3.2mm X 19.1mm. For self adhesive backing add suffix SAB to part number 65

66 Knitted Wire Mesh Gaskets with an Environmental Seal Technical Specifications (Continued) Solid Mesh to Silicone Sponge Carrier Solid Mesh to Neoprene Sponge Carrier Profile Profile Material Code Mesh Carrier Mon TCS S/St Alu Dia Ht W Part Number Other sizes are available on request Material Code Mesh Carrier Mon TCS S/St Alu Dia Ht W Part Number Other sizes are available on request 66

67 Knitted Wire Mesh Gaskets with an Environmental Seal Technical Specifications (Continued) Solid Mesh to Silicone Sponge Carrier Silicone Sponge Core to Silicone Sponge Carrier Profile Profile Material Code Mesh Carrier Mon TCS S/St Alu Ht W Ht W Part Number Other sizes are available on request Material Code Mesh Carrier Mon TCS S/St Alu Ht W Ht W Part Number Other sizes are available on request 67

68 Knitted Wire Mesh with an Environmental Seal Technical Specifications (Continued) Solid Mesh to Neoprene Sponge Carrier Neoprene Sponge Core to Neoprene Sponge Carrier Profile Profile Material Code Mesh Carrier Mon TCS S/St Alu Ht W Ht W Part Number Other sizes are available on request Material Code Mesh Carrier Mon TCS S/St Alu Dia Ht W Part Number Other sizes are available on request 68

69 Knitted Wire Mesh with an Environmental Seal Technical Specifications (Continued) Silicone Tube Core to Neoprene Sponge Carrier Neoprene Sponge Core to Neoprene Sponge Carrier Profile Profile Material Code Mesh Carrier Mon TCS S/St Alu Dia Ht W Part Number Material Code Mesh Carrier Mon TCS S/St Alu Ht W Ht W Part Number Other sizes are available on request Other sizes are available on request 69

70 Knitted Wire Mesh with an Environmental Seal Technical Specifications (Continued) Silicone Sponge Core to Silicone Sponge Carrier Silicone Tube Core to Silicone Sponge Carrier Profile Profile Material Code Mesh Carrier Mon TCS S/St Alu Dia Ht W Part Number Other sizes are available on request Material Code Mesh Carrier Mon TCS S/St Alu Dia Ht W Part Number Other sizes are available on request 70 Notice Information supplied in these data sheets is based on independent and laboratory tests which Kemtron believes to be reliable. Kemtron has no control over the design of customer s product which incorporates Kemtron s products, therefore it is the responsibility of the user to determine the suitability for his particular application and we recommend that the user make his own test to determine suitability. The product described in this data sheet shall be of standard quality, however the products are sold without warranty of fitness for a particular purpose, either expressed or implied, except to the extent expressly stated on Kemtron s invoice, quotation or order acknowledgement. Kemtron does not warrant that products described in this data sheet will be free of conflict with existing or future patents of third parties. All risks of lack of fitness, patent infringement and the like are assumed by the user.

71 Conductive Fabric Over Foam Gaskets Product Overview This product is manufactured from a synthetic polyester or nylon yarn which is plated to give electrical conductivity over the surface of the fibre and then woven in a traditional way so as to produce a conductive cloth. The cloth is then slit and wrapped over a soft polyether polyurethane foam core in a range of profiles and results in an economically priced conformable conductive gasket strip suitable for many applications. Applications The versatility of Conductive Fabric Over Foam and the huge variety of profiles available makes the product suitable for a wide range of applications where full EMC screening is required between component parts especially in high cycling and wiping applications and where low compression and excellent abrasion resistance are considerations. Typical applications include Cabinet doors. Panel gaskets. Grounding contacts. Card cage gaskets. Connector and IO gaskets. Consider the minimum land area on die cut parts, we would suggest that it is equal to the thickness of the material. Production Capability Kemtron holds large stocks of Conductive Fabric Over Foam profiles, which can be supplied to customers off the shelf or die or kiss cut or fabricated to their requirements. Gasket fabrication is a routine feature of our work enabling us to produce economic gaskets by maximising material usage, using a range of in-house cutting and stamping equipment, which is suitable for prototype, short and medium production runs, up to commercial quantities. Availability Profiles are available in 2100mm lengths with some obtainable in continuous length. Depending on the profile the product can be Cut to length. Die cut to form fabricated gaskets. Notched for 90 degree fabrication. Mitred. Supplied with clip on and edge mounting or with self-adhesive backing. Have fire resistant properties to UL94VO. Compression between 10% and 70%. Design Considerations Whilst a limited dust seal can be achieved, additional environmental sealing, if needed, is required. Consideration must be given to compression forces and corrosion compatibility. Notice Information supplied in these data sheets is based on independent and laboratory tests which Kemtron believes to be reliable. Kemtron has no control over the design of customer s product which incorporates Kemtron s products, therefore it is the responsibility of the user to determine the suitability for his particular application and we recommend that the user make his own test to determine suitability. The product described in this data sheet shall be of standard quality, however the products are sold without warranty of fitness for a particular purpose, either expressed or implied, except to the extent expressly stated on Kemtron s invoice, quotation or order acknowledgement. Kemtron does not warrant that products described in this data sheet will be free of conflict with existing or future patents of third parties. All risks of lack of fitness, patent infringement and the like are assumed by the user. 71

72 Conductive Fabric Over Foam Gaskets Ordering Information E xx X X X XXXXX Profile Foam Fabric Finishing / Length Attachment System Profile Guide Select from list Foam Fabric Nickel/Copper C12 Nickel /Copper C70 Silver C2 (Polyester Woven) (Polyester Ripstop) (Nylon Ripstop) Shielding Effectiveness 97.4dB 96dB 95dB Mil DTL83528C 20MHz to 10GHz Test Gasket 6.4mm x9.5mm Surface Resistivity 0.02Ω_ 0.066Ω_ 0.05Ω_ ASTM F390 Modified Fabric 1 = UL94HB 5 = UL94VO Bromine Free 6 = UL94VO 7 = UL94VO Recognised soft foam under the component program of Underwriters Laboratories Inc. In specified claddings and thicknesses Abrasion Resistance 1,000, , ,000 ASTM D 3886 Cycles Cycles Cycles Contact Resistance 0.08Ω 0.11Ω <1.0 Schlegel LP Kg load at 25.4mm Compression set <5% <5% <5% 70 C at 50% compression for 22 Hours 3 = Nickel/Copper C70 (Polyester Ripstop) 4 = Nickel/Copper C12 (Polyester Woven) 9 = Silver C2 (Nylon Ripstop) Finishing / Attachment System - = No pressure sensitive adhesive E = N = H = C = P = Z = 2Z / 2T / 2H = A = B = T = L = W = K = D = Die cut Narrow tape High shear PSA PSA in the centre PSA on inside leg Wide release liner 2 rows PSA on the same side PSA on adjacent side PSA on back side PSA PSA on lead edge or opposite seam side Wide PSA Kiss cut + PSA Conductive PSA for mechanical reasons Length In inches; if continuous Example = = *special minimum order quantity may apply

73 Conductive Fabric Over Foam Gaskets Profile Guide Rectangular Sections Height (mm) Width (mm) Profile Code E E ES E E EU ES ET E E E E E ET E ET EJ6* ET E E EC5* E97* EN ED E EG EB ET EA8* EU EU E E EC7* E E ED EN EG7* E EH4* E09* E07* E30* EU E E EM ES5 Height (mm) Width (mm) Profile Code ES E44* EC6* ED5* E EQ E E EM7* EN9* EM9* E E EB EP EN E E47* EN E EJ ES EP E EP EN E EN EJ ES ES ET E E EG9* EN EP EP E05* EG E E E84* E20* EP5* E E75* E49* E36* *special minimum order quantity may apply 73

74 Conductive Fabric Over Foam Gaskets Profile Guide Wedge E60 3.3mm x 13.2mm.130 x.402 EA7* 11.4mm x 16.0mm.448 x.630 E52* 4.0mm x 8.2mm.157 x.324 Self-Mounting E93* 2.5mm x 8.4mm.100 x.330 EB9 3.7mm x 6.5mm.145 x.256 E86* 18.8mm x 9.7mm.740 x.380 E27* 16.2mm x 5.8mm.638 x.230 Knife Edge E96 2.7mm x 8.0mm.106 x.315 E67 2.7mm x 11.3mm.106 x.445 EH6* 2.7mm x 11.3mm.106 x.445 E31 2.7mm x 11.3mm.106 x.445 E19* 6.4mm x 19.1mm.250 x.750 L Shape EA2* 3.8mm x 10.2mm.150 x.400 ED2* 5.0mm x 8.5mm.197 x.335 E13* 5.5mm x 12.0mm.217 x.472 E48* 7.9mm x 18.6mm.312 x *special minimum order quantity may apply

75 Conductive Fabric Over Foam Gaskets Profile Guide Bell Shaped Round EU7 2.5mm x 7.6mm.098 x.300 ET2 3.0mm x 8.00mm.118 x.315 E69* 2.5mm diameter.098 diameter T-Shape ED4* 3.9mm x 6.0mm.152 x.235 ED1* 4.0mm x 6.2mm.157 x.244 EA9 4.0mm x 6.2mm.157 x.244 EJ2 4.0mm x 6.2mm.157 x.244 EQ2* 4.8mm x 6.4mm.190 x.250 E41* 5.1mm x 4.8mm.200 x.190 E53* 7.6mm x 6.9mm.300 x.272 EH8* 10.0mm x 10.0mm.395 x.395 D-Shape E17 1.5mm x 3.8mm.060 x.150 ET6 1.5mm x 6.4mm.059 x.250 EG6* 1.8mm x 4.6mm.070 x.180 ES3 2.0mm x 6.0mm.079 x.236 EP1 2.0mm x 8.0mm.079 x.315 EJ8 2.0mm x 10.0mm.079 x.394 EK4 2.0mm x 12.7mm.079 x.500 E51 2.0mm x 17.1mm.080 x.675 EH2 2.0mm x 17.2mm.080 x.675 E57 2.3mm x 2.3mm.090 x.090 E45 2.3mm x 3.9mm.090 x.155 EJ9 2.3mm x 10.0mm.090 x.394 EK5 2.3mm x 12.7mm.090 x.500 ED7 2.3mm x 12.7mm.090 x.500 *special minimum order quantity may apply ES4 2.5mm x 6.4mm.100 x.250 ET9 2.5mm x 7.6mm.100 x.300 EU8 2.5mm x 8.0mm.100 x.315 EK1 2.7mm x 10.0mm.106 x

76 Conductive Fabric Over Foam Gaskets Profile Guide D-Shape EK6 2.7mm x 12.7mm.106 x.500 E87 2.8mm x 9.7mm.100 x.380 EJ5 3.0mm x 12.7mm.118 x.500 EA3 3.1mm x 3.8mm.120 x.150 EA1 3.1mm x 6.4mm.120 x.250 E26 3.1mm x 9.1mm.120 x.360 EK2 3.3mm x 10.0mm.130 x.394 EK7 3.3mm x 12.7mm.130 x.500 EM6 3.5mm x 9.5mm.140 x.375 E90 3.6mm x 6.4mm.140 x.250 EG4 3.8mm x 3.8mm.150 x.150 EK3 3.8mm x 10.0mm.150 x.394 EK8 3.8mm x 12.7mm.150 x.500 EA5 4.0mm x 6.0mm.156 x.236 E35 4.0mm x 7.4mm.156 x.292 E43* 4.0mm x 7.4mm.156 x.292 EH1 4.0mm x 12.7mm.157 x.500 EH7 4.0mm x 12.7mm.157 x.500 EM3* 4.0mm x 12.7mm.157 x.500 E50* 4.3mm x 9.7mm.170 x.380 EM5 4.3mm x 9.7mm.170 x.380 E64* 4.7mm x 12.2mm.185 x.480 EB1* 4.7mm x 12.2mm.185 x.480 E04 4.8mm x 7.6mm.189 x.300 E50* 5.0mm x 17.2mm.197 x.675 EM2* 5.0mm x 17.2mm.197 x.675 EJ1 5.5mm x 12.7mm.217 x.500 E10 6.4mm x 9.5mm.250 x.375 EA6* 6.4mm x 9.5mm.250 x.375 EP4 8.4mm x 10.0mm.335 x EH5 9.53mm x 12.7mm.375 x.500 *special minimum order quantity may apply

77 Conductive Fabric Over Foam Gaskets Profile Guide C-Fold E56* 6.1mm x 7.4mm.240 x.292 EB6* 6.1mm x 7.4mm.240 x.292 E21 6.4mm x 5.9mm.250 x.234 EC3 6.4mm x 7.1mm.250 x.280 EH3 8.0mm x 8.0mm.315 x.315 EG3* 9.8mm x 10.7mm.385 x.420 EM4* 9.8mm x 10.7mm.385 x.420 E98 9.8mm x 10.7mm.385 x.420 E98 Riveted* 9.8mm x 10.7mm.385 x.420 EH9* 9.8mm x 10.7mm.385 x.420 E55* 9.8mm x 12.2mm.385 x.480 E mm x 10.9mm.385 x.430 ED8* 11.4mm x 16.0mm.448 x.630 E mm x 10.7mm.465 x.420 EP7 11.8mm x 10.7mm.465 x.420 E mm x 14.7mm.675 x.580 ED8* 18.0mm x 14.2mm.710 x.560 E mm x 14.0mm.940 x.550 C-Fold EC2* 9.0mm x 11.0mm.354 x.433 EG5 9.5mm x 12.7mm.374 x.500 *special minimum order quantity may apply 77

78 Beryllium Copper Finger Stock Product Overview Beryllium copper (BeCu) spring finger and contact gaskets are manufactured by punching or etching thin BeCu strip which is pressed and formed into the required final shape and then heat treated to give it memory. Due to their high conductivity, BeCu gaskets provide good EMI/RFI shielding together with low closure force properties and are available in a number of plated finishes and mounting styles. In certain closing applications the wiping action enhances shielding performance. The end product results in a low resistance contact finger with excellent anti-corrosion properties that remains flexible within acceptable limits for many years. Application BeCu fingers are suited for use in high cycling RFI/EMI and EMP applications where frequent access is required as their construction makes them resistant to fatigue and only low compression forces are needed. They are suited to high and low temperature applications and their wiping action makes them ideal for use in: Cabinet doors. Access panels. Personnel doors in screened rooms and containers. Shielded rooms. Grounding contacts. Ensure galvanic compatibility with mounting surfaces. Fixing method must be appropriate to the application Exposed gaskets are susceptible to damage, catching on clothing etc. Production Capability BeCu gaskets are usually supplied in 406mm (16 ) lengths, but can be cut to requirements and, depending on the profile, are available in continuous longer lengths. To ensure galvanic compatibility gaskets can be supplied in a range of finishes including tin, nickel, zinc/clear chromate, gold, silver and nickel. 78 Availability There are short lead times on most gaskets, which are available in a large range of standard profiles in strips, generally 406mm (16 ) long. Longer lengths are available with some in continuous lengths. Gaskets can be applied using adhesive tape, or can be slot mounted, clipped on or soldered and in addition to the standard finish can also be supplied in Tin, Nickel and Silver finishes. Design Considerations This product does not provide an environmental seal. Over-compression can result in damaged fingers and loss of effectiveness. Mounting styles include clip-on, stick-on, snap-on, low profile and hook-ondium or large commercial production runs. Notice Information supplied in these data sheets is based on independent and laboratory tests which Kemtron believes to be reliable. Kemtron has no control over the design of customer s product which incorporates Kemtron s products, therefore it is the responsibility of the user to determine the suitability for his particular application and we recommend that the user make his own test to determine suitability. The product described in this data sheet shall be of standard quality, however the products are sold without warranty of fitness for a particular purpose, either expressed or implied, except to the extent expressly stated on Kemtron s invoice, quotation or order acknowledgement. Kemtron does not warrant that products described in this data sheet will be free of conflict with existing or future patents of third parties. All risks of lack of fitness, patent infringement and the like are assumed by the user.

79 Beryllium Copper Finger Stock Technical Specifications Ordering Information Part No i.e. Other finishes available are Finish (yy plated finish) Solderable unplated 01 Clean and Bright (unsolderable) 02 Gold 03 Silver 04 Bright Tin 17 Bright Nickel 20 Zinc/Clear Chromate 15 Electroless Nickel 18 Finger Strips are supplied with a clean and bright finish as standard. Handling Considerations BeCu gaskets are fully RoHS compliant. There are no special toxic hazards associated with the handling of copper beryllium alloys. However cuts and abrasions should be treated by normal first aid methods and it is advised that after contact with copper-beryllium alloys the hands should be washed before food is eaten. Care should also be taken, as with other metal alloys, to remove all metal particles from the wound whilst normal hygiene standards should be observed. Further information can be found in The Health and Safety Executive (UK) Guidance Note EH13 Beryllium health and safety precautions. Beryllium copper alloy 25 (CA172) is used in these applications for maximum spring properties of strengthand fatigue resistance. Ref Chemical Composition Beryllium % Cobalt plus nickel 0.20% Min. Cobalt plus nickel plus iron 0.6% Max. Copper Balance Physical Properties (heat treated) Electrical conductivity (% IACS) Modulus of elasticity (GPa) Mechanical Properties (heat treated) Temper 1 2Hard Tensile strength. (MPa.) 1275 Min. Yield strength.2% offset (MPa) 160 Min. Manufacturing Tolerances (mm) Pitch ±0.127 Length ±1.52 Spring Height ±0.51 Cut Length ±0.51 Finish Specification Solderable unplated NA Clean and Bright (unsolderable) NA Gold Mil-G Silver QQ-S-365 Bright Tin MIL-T Bright Nickel QQ-N-290 Zinc/Clear Chromate NA Electroless Nickel MIL-C

80 Beryllium Copper Finger Stock Technical Specifications (Continued) Slot Mounting Clips Designed to be used in parallel slots in sheet metalwork, suitable for both shielding and grounding and can be used in both compression and wiping action. Typical Applications Front Panels, Plug in Units, Subrack Assemblies. General Purpose Stick on Gaskets For enclosure applications Top View E Slot D Pitch Top View A Length E Slot Side View D Pitch B Approx. Length Right View M F B F C Recommended Hole Mounting Pattern C M L Dim A Dim B Dim C Dim D Dim E Dim F Length Part Number YY YY YY YY YY YY YY N Material Thickness Recommended slot dimensions Dim A Dim B Dim C Dim D Dim E Dim F Part Number Dim L Dim M Dim N XX-YY XX-YY XX-YY XX-YY XX-YY XX-YY M Length of slot is dependent on the number of fingers used Ordering Information Part No i.e (YY plated finish) Part is available in Extra Soft form, add ES to prefix i.e 1100ES-014 Ordering Information 80 Part No i.e XX(Number of fingers)-yy(plated finish) Most parts can be supplied in continuous coils or 406mm lengths.parts can be supplied in Extra Soft form, add ES to prefix i.e.1100es-010 etc.

81 Beryllium Copper Finger Stock Technical Specifications (Continued) General Purpose Stick on Gaskets Profile Profile C A D B A E J Double Adhesive Tip Touches Transfer Tape Mounting Surface B Double Adhesive Tape Dim A Dim B Dim C Dim D Dim E Length Part Number YY YY C D E H Mounting Surface K L Smallest Opening YY Ordering Information Part No i.e (YY plated finish) Above parts are available in Extra Soft form, add ES to prefix i.e. 1100ES-95 1 Profile D A B C D E H J K L Len Coil Part Number mm Len mtr NA YY NA NA YY NA YY NA YY NA NA YY NA YY NA NA YY NA NA YY NA YY NA NA YY NA YY NA YY NA NA YY B A Standard versions /537/538 Standard version with teardrop /520/540 Right angled version /525/535/544/545 With Magnefil /548 (provides increased magnetic shielding) Ordering Information Double Adhesive Tape C Part No i.e (YY plated finish) Dim A Dim B Dim C Dim D Dim E Length Part Number YY YY YY Above parts are available in Extra Soft form, add ES to prefix i.e.1100es-500 Ordering Information Part No i.e (YY plated finish) Above parts are available in Extra Soft form, add ES to prefix i.e. 1100ES

82 Beryllium Copper Finger Stock Technical Specifications (Continued) General Purpose Stick on Gaskets Profile D Thickness A C Rivet Mounted Gasket Strips This gasket has a continuous central strip on top of the gasket enabling it to be used in a longitudinal sliding action as well as wiping. A retention clip can be supplied to hold the gasket in placewhen used with t he sliding action. Profile E F B M N Dim A Dim B Dim C Dim D Dim E Dim F Length Part Number YY 38,1 38, YY YY YY D Ordering Information Part No i.e (YY plated finish) B A C E Rivet Mounted Gasket Strips Designed for use in a wiping action such as on drawers and PC board connections. Profile Push Rivet Dim A Dim B Dim C Dim D Dim E Length Part Number Dim M Dim N No. Rivets YY YY YY M N Ordering Information Part No i.e (YY plated finish) 38,1 C L Slot 38,1 Above parts are available in Extra Soft form, add ES to prefix i.e.1100es-913 The Rivet mount version is available with retention clips: Part No. Used On D E B A C Push Rivet Dim A Dim B Dim C Dim D Dim E Length Part Number Dim M Dim N No. Rivets YY YY YY Ordering Information Part No i.e (YY plated finish) Above parts are available in Extra Soft form, add ES to prefix i.e.1100es-952

83 Beryllium Copper Finger Stock Technical Specifications (Continued) Foldover Stick on Gaskets A general purpose gasket but the contact finger is protected within an enclosed end, thus preventing accidental damage when used in high access areas. Profile Twisted Finger Gaskets A general purpose cost effective gasket designed for use where small gaps need filling. Profile A C H In Flat E D In Flat H D E B Double Adhesive Transfer Tape Smallest Opening F A B C D E F Length mm Coil Part Number Length mtr YY YY YY C A At Smallest Opening B Free Position Double Adhesive Transfer Tape A C YY Ordering Information H Part No i.e (YY plated finish) Above parts are available in Extra Soft form, add ES to prefix i.e. 1100ES-515 B Free Position A Large Enclosure Door Gaskets Suitable for large enclosure doors such as shielded rooms, communication cabins etc. To be used in a wiping application and should be fixed with screws, rivets or soldered in place. Profile B I A C L H G E D Double Adhesive Transfer Tape A B C D E H Length mm Coil Part Number Length mtr YY NA YY YY YY NA YY YY YY YY YY Ordering Information Mounting Surface Smallest Opening Part No i.e (YY plated finish) Above parts are available in Extra Soft form, add ES to prefix i.e. 1100ES-550 A B C D E F G H I L Length mtrs Part Number YY YY 83

84 Beryllium Copper Finger Stock Technical Specifications (Continued) Clip On Twisted Finger Gaskets Designed for clipping on to a panel, lances are available to ensure a secure fixing. Profile A Clip On Gaskets (Continued) D Lance Detail I 2,0 K 1,3 Semiellipse 2,54 D Lance Recommended Hole Size B J C L of Hole Radius C* E Part No D CL I B E A B C D E F Length mm Coil Part Number Length mtr With D Lance YY YY YY YY YY YY YY 568 Ordering Information Part No i.e (YY plated finish) Above parts are available in Extra Soft form, add ES to prefix i.e. 1100ES-553 Clip On Gaskets Designed for clipping on to a panel, lances are available to ensure a secure fixing. Part No /604/605/606/607 Smallest H Opening E A E D B C* (Inside) H B A D C* (Inside) F F G G G A B C D E F G H Length Lance Location Dims Lance to Lance Dims Part Number YY YY YY YY YY YY YY YY YY YY YY YY YY YY YY YY YY YY YY YY YY YY YY YY Parts with no lance, (available as options): 610/614/619/620/628/629/630 Parts with square lance: 612/650 Parts with T lance (suitable for softer materials): 604/605/611/621/631/633 Parts with D lance (2.54 Ø hole required in material): 603/606/607/613/622/632/634/645 Ordering Information Part No i.e (YY plated finish) F Mini Clip-On A C* J D 84 Above parts are available in Extra Soft form, add ES to prefix i.e. 1100ES-603

85 Beryllium Copper Finger Stock Technical Specifications (Continued) Clip On Gaskets (Continued) Designed for clipping on to a panel, lances are available to ensure a secure fixing. Clip On Perpendicular Edge Grounding Designed to be used on the top edge of enclosure walls and from PC cards to back planes. Part No Part No (88 Fingers) 419,76 ± 2,54 0,46 ± 0,03 Slot 4,77 ± 0,03 Pitch A A 0,51 Slot A 0,76 7,62 Pitch D Lance 1,19 Semi-Ellipse 2,03 Wide TYP 9,53 4,55 A 5,28 Section A-A Compression View 0,76 1,62 1,52 2,99 0,08 0,10 4,64 0,63 0,51 12,98 0,51 1,60 14,07 0,88 1,78 2,77 Part No Ordering Information 1,4 45º R 0,89 Part No i.e. R 0, (YY plated finish) 2,12 0,5 7,75 Above parts are available in Extra Soft form, add ES to prefix i.e. 1100ES-637 3,27 5,38 0,25 303,4 13,84 Pitch 1,14 Slot 4,27 2,03 6,35 C L of Lance & Finger Ordering Information Part No i.e (YY plated finish) Above parts are available in Extra Soft form, add ES to prefix i.e. 1100ES

86 Beryllium Copper Finger Stock Technical Specifications (Continued) Clip On Perpendicular Gasket Designed to be used on the top edge of enclosure walls giving good shielding between wall and mating surface. Profile Longitudinal Grounding Strips (Continued) Part No ,57 1,42 406,4 Pitch 12,7 12,70 Adv. 6,35 Pitch 0,76 Slot 2,29 See detail A See detail B Detail A 5,97 30º Ref. 405,6 1,51 12,7 Pitch (Ref) 8,26 6,35 0,89 Rad. 0,13 Full R (Typ.) 1,42 (Ref) 13,82 6,50 Detail B CL of 7,62 RAD 7,27 (Ref) 45º 4,58 Ordering Information R 7,62 R 1,27 3,68 Part No i.e. Part No (YY plated finish) Above parts are available in Extra Soft form, add ES to prefix i.e. 1100ES-656 1,3 9,7 5,3 31,8 2,5 typ Ref 15,2 Longitudinal Grounding Strips 20,3 Designed for grounding where a sliding action is required such as rack mounting, drawer assemblies etc. 5,3 Double Adhesive Tape 31,8 Approx. Length 476,3 2,8 Dia. Part No ,22 0,51 7,49 Initial compression against this side 0,1 1,80 5,46 20,01 1,52 R 0,76 R 0,38 7,49 0,90 4,44 1,78 7,6 Ref. Ordering Information Smallest Opening 4,46 3,05 R Part No i.e (YY plated finish) Above parts are available in Extra Soft form, add ES to prefix i.e. 1100ES

87 Beryllium Copper Finger Stock Technical Specifications (Continued) Flexible Contact Strips Designed for applications where a continuous irregular path must be followed, able to conform to tight radius comers. Can be clipped into a groove or surface mounted by soldering or conductive adhesive. Profile Contact Strips A large range of standard contact strips, which can be used for grounding or shielding. Strips can also be formed into rings. Part No Part No A C 1,19 1,02 Slot 4,19 Pitch 1,3 R 14,0 11,4 2,0 2,3 Spher. R. 1,3 0,8 B D 4,78 L 4,8 0,13 2,3 Flat Bank Part No Part No F E Recommended Groove Size 4,75 Pitch 1,19 Slot 1,5 2,3 Spher. R. 3,3 0,8 6,9 5,1 A B C D E F Length mm Part Number YY 16,0 R 22,6 3,3 R YY 0,13 L Ordering Information Profile Part No i.e (YY plated finish) Above parts are available in Extra Soft form, add ES to prefix i.e. 1100ES-921 Pitch Slot B L Part No Part No ,3 Spher. R. 2,0 Spher. R. 1,0 0,10 7,6 8,6 1,3 0,15 7,9 9,7 Part No Part No Part No ,3 Spher. R. 2,3 R. 1,0 7,6 8,6 19,8 0,10 16,8 7,9 9º 2,3 0,25 Part No ,0 Spher. R. 35º-45º 2,0 1,5 R. 28,7 26,2 1,5 0,25 Part No

88 Beryllium Copper Finger Stock Technical Specifications (Continued) Contact Strips (continued) A large range of standard contact strips, which can be used for grounding or shielding. Strips can also be formed into rings. Part No Part No ,5 2,3 0,4 R. 2,3 45º 2,3 R. 1,5 R Part No ,4 R. 16,8 23,4 19,6 16,0 22,6 Part No ,13 0,13 Fingers Opposite 1,19 Slot 4,75 Pitch 1,5 R. Profile Part No R 6,4 Pitch Slot L B Part No Part No Part No L Fingers Opposite 1,19 Slot 4,75 Pitch 1,5 R. Part No ,8 3,3 0,5 R. Inside 1,0 R. 0,1 1,5 R 3,5 1,8 L Part No Part No Side View 1,5 R. 3,3 3,3 R. 5,6 0,8 12,2 7,6 3,3 R. 16,0 0,3 19,8 3,3 0,15 4,8 7,1 3,3 R. Profile Part No ,75 Pitch 1,19 Slot 1,3-0,5 R. 1,5 0,8 3,3 0,8 R. R. 1,5 R. B 2,3 0,13 L Profile Part No Part No Pitch Slot 5,8 2,0 2,3 B 1,3 3,3 R. 16,6 2,3 R. 7,9 L 0,13 Part No ,1 5,1 R. 6,4 R. 22,6 Part No Part No ,13 0,8 R. 0,8 R. Part No Part No Part No ,8 R. 7,1 3,3 0,8 2,0 2,3 0,8 Max 0,25 3,3 3,3 2,3 4,8 R. 0,25 7,1 3,3 R. 22,6 0,13 R. 23,4 Part No ,1 Part No ,0 16,8 0,13 0,13 Part No Part No

89 Beryllium Copper Finger Stock Technical Specifications (Continued) Contact Strips (Continued) A large range of standard contact strips, which can be used for grounding or shielding. Strips can also be formed into rings. Profile 1,91 Pitch 0,64 Slot Part No B 1,5 R. 6,9 L 12,7 Part No Part No ,3 6,4 2,3 0,8 R. 0,25 0,5 R. 4,3 4,6 0,8 0,10 6,9 4,8 2,0 Spher R. 2,3 0,15 Part No ,8 2,8 4,37 Pitch 1,19 Slot 3,0 Part No ,1 R. 0,8 R. 23,1 16,8 0,25 5,1 9,7 2,3 R. 11,2 L 2,8 Part No Part No ,25 4,1 3,99 Pitch 1,02 Slot 7,9 Part No º 30º 23,9 5,6 R. 3,3 R. 18,0 8,6 0,15 9,7 3,99 Pitch L To Outside 6,4 1,02 Slot Profile 1,91 Pitch 0,64 Slot 9,1 Fingers may or may not be opposite 4,1 0,13 5,6 L Part No L Part No ,41 1,5 Slot 3,91 Pitch 1,6 1,0 3,3 Spher R. 1,3 2,0 Spher. R. 0,8 R. 9,1 16,3 14,0 21,3 6,4 0,15 L 0,3 89

90 Beryllium Copper Finger Stock Technical Specifications (Continued) Contact Strips (Continued) A large range of standard contact strips, which can be used for grounding or shielding. Strips can also be formed into rings. Part No Ref 1,3 Ref 1,0 Part No ,5 Ref 0,5 1,5 0,10 0,30 2,54 Pitch 7,9 Flat 4,8 0,5 L 0,10 L 1,5 0,5 R. 0,30 1,3 Pitch 3,3 7,9 Pitch Slot B Length Fingers Part Number YY YY YY YY YY YY YY YY YY YY YY YY YY YY YY YY YY YY YY YY YY YY YY YY YY YY YY YY YY YY YY Contact strips can also be supplied as rings, contact the sales office for further details. Ordering Information Part No i.e (YY plated finish) Above parts are available in Extra Soft form, add ES to prefix i.e. 1100ES-105 * Selectively deposited silver or gold can be applied to the end of contacts to enhance conductivity, see plating finishes for ordering suffix. 90

91 Conductive Foam Product Overview Kemtron conductive foam is a low density PET and polyurethane foam which is copper + nickel coated throughout giving X,Y and Z axis low resistance electrical conductivity thereby giving excellent EMI shielding performance when used as an EMI gasket. The material is UL94V-1flame retardant. Application Low compression sheet gasket material suitable for die cutting or slitting for gasket applications such as I/O panels, backplanes, connectors, access panels etc. Availability Thickness: 1.5mm, 2.3mm, 3.4mm Rolls up to 56cm wide with or without conductive transfer adhesive. Die cut to drawing. Strips to custom widths. Design Considerations These materials are not suitable for joining or fabricating. Gaskets are only available as a single part. The material is not suitable in sliding applications. Recommended compression: 30%. Self-adhesive backing (conductive). Minimum material width should not be less than 2mm or at least the material thickness in any part of the gasket. If this cannot be achieved around fixing holes consider using a slot. Shielding effectiveness Thickness Product Surface Volume Shielding effectiveness code resistivity resistivity 100Mhz 1GHz 1.5mm Ω/sq 0.015Ω/sq 80dB 83dB 2.3mm Ω/sq 0.014Ω/sq 88dB 104dB 3.4mm Ω/sq 0.013Ω/sq 80dB 103dB Notice Information supplied in these data sheets is based on independent and laboratory tests which Kemtron believes to be reliable. Kemtron has no control over the design of customer s product which incorporates Kemtron s products, therefore it is the responsibility of the user to determine the suitability for his particular application and we recommend that the user make his own test to determine suitability. The product described in this data sheet shall be of standard quality, however the products are sold without warranty of fitness for a particular purpose, either expressed or implied, except to the extent expressly stated on Kemtron s invoice, quotation or order acknowledgement. Kemtron does not warrant that products described in this data sheet will be free of conflict with existing or future patents of third parties. All risks of lack of fitness, patent infringement and the like are assumed by the user. 91

92 Connector Gaskets for RFI/EMI Shielding Product Overview Kemtron manufacture a range of gaskets to suit many standard size connectors which require an EMI/RFI gasket with optional environmental seal. The choice of material is vast and connector gaskets are available from virtually all of the flat sheet EMI materials manufactured by Kemtron. Listed below are a range of gaskets available from our own tools, also a list of the more common materials and thicknesses. If those listed below do not meet with your exact requirements, we would be pleased to manufacture gaskets to your own design using inexpensive tooling. 92 Notice Information supplied in these data sheets is based on independent and laboratory tests which Kemtron believes to be reliable. Kemtron has no control over the design of customer s product which incorporates Kemtron s products, therefore it is the responsibility of the user to determine the suitability for his particular application and we recommend that the user make his own test to determine suitability. The product described in this data sheet shall be of standard quality, however the products are sold without warranty of fitness for a particular purpose, either expressed or implied, except to the extent expressly stated on Kemtron s invoice, quotation or order acknowledgement. Kemtron does not warrant that products described in this data sheet will be free of conflict with existing or future patents of third parties. All risks of lack of fitness, patent infringement and the like are assumed by the user.

93 Connector Gaskets for RFI/EMI Shielding Technical Specifications MIL Connector Gaskets D Connector Gaskets 95 Elastomer D Type Range 91 Connector Gaskets MIL-C Shell Size Dim A Dia B Dim C Dia D No.Pins A B C D E F G Metallic D Type Range 92 Connector Gaskets MIL-C-5015 Shell Size Dim A Dia B Dim C Dia D Material & Part No. No.Pins A B C D E F G BeCu SS How To Order 93 Connector Gaskets MIL-C Shell Size Series Dim A Dia B Dim C Dia D 8 II I II I & IV II I & IV II I & IV II I & IV II I & IV II I & IV II I & IV II I & IV Material Thickness Material Code SNG SSA SSC Select the table number EG: 93 then choose material from the list EG: 3 followed by the shell size or for D connectors the number of pins / EG: shell 18 Example 933 / 18 = connector gasket to suit MIL-C dimensions using Kemtron 410 material in thickness 1.6mm in shell size 18 93

94 Aluminium Honeycomb Air Ventilation Panels for RFI/EMI Shielding Product Overview Aluminium Honeycomb Air Ventilation Panels consist of an aluminium honeycomb foil held in a rigid extruded aluminium mounting frame. The foil, formed and laminated into a series of honeycomb cells that are glued and perforated or laser welded at the join, ensures a conductive path at each join. Although the foil is conductive in all directions, to enhance EMI performance, two pieces of honeycomb polarised at 90º to each other are recommended. The frame can be supplied with an integral or separate EMI/RFI gasket, and can be treated with a variety of finishes to provide corrosion protection or improve conductivity. How do Honeycomb vents work: The principle is that of Waveguide beyond cutoff. The honeycomb vent is series of tubes that acts as a waveguide, guiding electromagnetic waves into or out of the enclosure, but as the tubes are long enough then it attenuates those waves. Typically the tube should be at least 3 times as long as the diameter. Good practice is 4 times. Therefore a 3.18mm cell should be 12.7mm long.honeycomb material is used because it offers high shielding performance, light weight and good airflow. A standard range of Honeycomb vents are available, drawings and part numbers are shown at the end of this data sheet. 94

95 Aluminium Honeycomb Air Ventilation Panels for RFI/EMI Shielding Product Overview (Continued) Applications Ventilation panels are designed for use in electronic enclosures where good air flow is required for cooling and ventilation but where EMC compliance must be ensured. Typical applications are: Electronic Enclosures. Air Conditioning Units. Fan housings. EMC Racks. Communication shelters. Availability An extensive range of aluminium extrusion mounting frames are available from stock offering a choice of mounting methods and sizes. Available as custom sizes with no additional cost. Frames can be supplied with fixing holes or captive threaded inserts to aid mounting. Honeycomb can be supplied in a number of configurations to suit different EMI/RFI Shielding performance requirements. Such as straight through, polarized and a choice of cell size. Standard perforated honeycomb is available with 30, 45, 60 and 90 angles from stock and Laser welded aluminium honeycomb is also available to special order. For vulnerable situations weld mesh or expanded aluminium kick plates can be fitted. Removable dust filters and integral insect screens can also be provided. A range of low cost standard fan vents are available to meet commercial applications where lower performance is acceptable, consisting of one layer of aluminium honeycomb held in a plastic frame. Design Considerations Any environmental conditions such as moisture and dust control including: Air Flow requirement. External louvers for rain protection. Drain holes. Any additional gasketing. Constructional requirements and finishes including: Angled honeycomb for rain protection or directional air flow. Rigidity of vent frame and enclosure so as to prevent bowing of either surface when compressing the gasket. Fixing requirements e.g. holes or threaded inserts ensuring appropriate position and size of hole-centres. (Holes in the corners of the frame should be avoided.) If specifying captive inserts in both sides of the frame off-set the positions by 10mm minimum. Round vents tend to be an expensive option due to the complexity of manufacturing method. Fully welded corners. Type of gasket required. Frame style. Honeycomb configuration. Corrosion, electrical conductivity etc, (see Finishes section) Weld mesh or expanded aluminium kick plates Removable dust filters and integral insect screens can be provided Production Capabilities Kemtron manufacture its range of EMC vent panels using the latest technology and, with the exception of painting and plating, all processes are kept in house, giving us flexibility and total control over quality. Kemtron has invested heavily in this area making us the market leaders for price, delivery, quality and availability Fully programmable CNC machines for the notching & cutting of the frame extrusions and drilling of exact and repeatable holes combined with the latest TIG welding equipment allows Kemtron to offer a fast delivery of its competitive range of aluminium vent panels produced to customer designs. This advanced technology also eliminates the need for additional tooling and set-up charges. Kemtron holds a large range of aluminium extrusions and aluminium honeycomb in stock. In addition to vent panels, Kemtron manufactures a huge range of EMI shielding products, including conductive Elastomers, oriented wire, knitted wire mesh, connector gaskets. Vent panels made with styles 1701, 1703, 1705, 1706 & 1707 are supplied with 3 corners notched and the 4th joined corner welded and have an external corner radii of 3mm. 95

96 Aluminium Honeycomb Air Ventilation Panels for RFI/EMI Shielding Product Overview (Continued) Honeycomb specification and availability: Kemtron uses 5052 grade aluminium foil which is a lightweight material offering superior strength and corrosion resistance over commercial grade aluminium foils. It meets all the requirements of MIL-C Kemtron s standard honeycomb vent uses 2 layers of 1 /8 cell X ¼ thick laid at 90, this is known as cross cell. Cross cell honeycomb improves shielding performance by eliminating any polarizing effects. Standard straight cell sizes & thicknesses held in stock 3.2mm (0.125 ) cell x 12.70mm (0. 50 ) thick 3.2mm (0.125 ) cell x 6.35mm (0.25 ) thick 1.6mm ( ) cell x 6.35mm (0.25 ) thick 3.2mm (0.125 ) cell x 3.2mm (0.125 ) thick Standard slant cell sizes, angles & thicknesses held in stock 3.2mm (0.125 ) cell x 6.35mm (0.25 ) thick x mm (0.125 ) cell x 6.35mm (0.25 ) thick x mm (0.125 ) cell x 6.35mm (0.25 ) thick x 60 96

97 Aluminium Honeycomb Air Ventilation Panels for RFI/EMI Shielding Product Overview (Continued) Frame styles available Frame styles 1701,1702,1703,1704 and 1707 will accommodate 2 layers of 3.2 x 6.35mm thick honeycomb, one layer of 3.2mm cell x 6.35mm thick and one layer of 3.2mm x 6.35mm thick angled honeycomb or one layer 12.7mm thick honeycomb Frame styles 1705, 1706 and 1709 will accommodate 1 layer of 3.2 or 1.6mm cell x 6.35mm thick honeycomb. Also possible to accommodate 2 layers of 3.2mm cell x 3.2mm thick honeycomb. Frame style 1708 is a dividing/support bar for large vents. Vents are normally supplied with three notched and one welded corner to achieve the best trade off between cost and performance. This combined with an EMC gasket is normally sufficient for all but the most demanding EMC specifications. In the event that the best possible attenuation is required all corners can be supplied fully welded. Please note that styles 1702 & 1704 are always supplied fully welded due to the nature of their construction. Notched corner Fully welded corner Fully welded corner 97

98 Aluminium Honeycomb Air Ventilation Panels for RFI/EMI Shielding Product Overview (Continued) Finishes Vent panels can be supplied with a range of finishes including: Painted. Tin or nickel plating. Kempass (RoHS ) Aluminium Passivation process. Trivalent chromium (RoHS compliant) or Hexavalent chromium. Kemtron s standard finish (Kempass) for aluminium vent panels fully meets the RoHS directive and replaces Alocrom1200 which is a hexavalient chromium process. Kemtron s in-house process applies a permanganate passivation which is a chromate free, inorganic and non toxic coating. The process produces a dense, uniform coating consisting of aluminium and reduced manganese oxides giving a light yellow colour to the surface. The surface finish is conductive with a low contact resistance equalling Alocrom It also meets all requirements of MIL-C-5541E for corrosion and electrical conductivity. We are also able to offer a comprehensive range of painted finishes to complement our standard Kempass finish. Using industry leading wet paint solutions from Trimite, we offer full painting and preparation to DEF STAN specifications including matt and gloss finishes. In addition we can also offer Infra Red Reflecting (IRR) matt finishes complying with DEF STAN 00-23, and STANAG For less critical / commercial applications requiring a protected finish we recommend polyester powder coating. This is tough material that offers excellent resistance to fresh and saltwater, petrol, linseed and penetrating oils, along with limited resistance to various acids. We are happy to advise on specific examples if required. As the epoxy process is an electrostatic method, it offers excellent penetration of the honeycomb cells, further aiding resistance to corrosion. With both processes, we are able to offer a full range of colours to RAL/BS charts. 98

99 Aluminium Honeycomb Air Ventilation Panels for RFI/EMI Shielding Product Overview (Continued) Gaskets for vents Knitted wire mesh = Frames with a gasket groove. Orientated wire in silicone. Knitted Monel wire mesh with a Neoprene sponge carrier 2.4mm thick. Beryllium Copper finger stock. Other gasket types are available if required Knitted wire mesh with neoprene gasket Beryllium copper gasket Kick Plates Aluminium honeycomb is fragile so for high traffic areas or where honeycomb damage could easily occur kick plates can be fitted. Two types are stocked as standard, however custom designs to customers specific requirements (i.e louvred openings) are available. Expanded aluminium provides maximum protection but reduces air flow Oriented wires in silicone gasket Knitted wire mesh gasket Woven stainless steel provides lower protection but higher air flow. 99

100 Aluminium Honeycomb Air Ventilation Panels for RFI/EMI Shielding Product Overview (Continued) Fan Vents A range of low cost plastic EMC vents for use with 80mm, 92mm & 120mm fans. They provide EMC shielding where applications demand a low cost solution, whilst still providing an adequate shielding performance. A Hi-impact ABS UL94V-0 fire retardant moulding is fitted with one layer of 3.2mm cell x 6.35mm thick honeycomb and a nickel/copper fabric gasket to ground the honeycomb to the metalwork. The vents have 4 countersunk holes to suit standard fan mountings. Measured shielding performance in accordance with Mil Std 285 (80mm size tested) Frequency Field Typical (db) 200KHz H MHz E MHz P 85 2GHz P 74 10GHz P 58 Type A B C Kemvent mm 8mm 45.5mm Kemvent mm 9mm 66.0mm Kemvent mm 10mm 84.5mm Kemvent mm 10mm 97.0mm Kemvent mm 10mm 125.0mm 100

101 Aluminium Honeycomb Air Ventilation Panels for RFI/EMI Shielding Product Overview (Continued) Optional Removable Dust Filters and Insect Screen Dust Filter Dust filters are made with either of the following aluminium frames; 1701, 1705, 1706, 1707 & 1709 which holds a polyester polyurethane dust filter. This is held in place on one side by a stainless steel weld mesh. This frame then mounts on to one side of the honeycomb vent panel by captive screws, a thin soft gasket is the interface between the honeycomb vent and the dust filter. The foam filter is easily removed for cleaning with a mild detergent and rinsed with water. A range of different filter options are available. 10, 20, 30, 45, 60 and 80 pores per inch stocked in 6.4mm and 12.7mm thicknesses, flame retardant versions are available. Aluminium honeycomb vent panels fitted with removable dust filters usually require assisted air flow. Insect Screen This is a woven aluminium cloth inserted on one face or between the honeycomb and provides protection from the ingress of insects. Wire dia 0.28mm open area 66%. 101

102 Aluminium Honeycomb Air Ventilation Panels for RFI/EMI Shielding Product Overview (Continued) Frame Styles Dividing/support bar 102

103 Aluminium Honeycomb Air Ventilation Panels for RFI/EMI Shielding Technical Specifications Tolerances Air Flow Results Graph Standard tolerances for overall finished vent dimensions are +/- 0.8mm. Standard tolerances on hole centres are +/- 0.4mm. Typical corner radii on frame styles 1701, 1703, 1705, 1706 & 1707 are R3.0mm & 1704 frame styles have square corners and are fully welded. Specifications Pressure Drop (Pa) Aluminium Frame 6063-T6 Aluminium Honeycomb Monel Wire Neoprene sponge 5052 grade BS3075 NA13 Mil-R-6130 Type 11 grade A condition soft Flow Speed (m/s) Beryllium Copper alloy 25 (CA172) Silicone Rubber ZZ-R-765 Class 2 Grade 40 Graph Key Aluminium Wire 5056 Type 5 60 Type 5 45 EMC Performance (db) Honeycomb Type Frequency Field Type 1 Type 2 Type 3 Type 4 Type 5 Type 6 200kHz H Type 5 30 Type 4 & Type 6 Type 3 Type 2 Type 1 100MHz E MHz P GHz P GHz P Honeycomb Type 1 Type 2 Type 3 Type 4 Type 5 Type 6 2 layers 3.2cell x 3.2mm thick honeycomb (total 6.4mm) 1 layer 3.2cell x 6.35mm thick honeycomb 1 layer 1.6cell x 6.35mm thick honeycomb 2 layers 3.2cell x 6.35mm thick honeycomb (total 12.7mm) 1 layer 3.2cell x 6.35 thick honeycomb + 1 layer 3.2cell x 6.35mm thick slant honeycomb (total 12.7mm) 1 layer 3.2cell x 12.7mm thick honeycomb Honeycomb Combinations Frame Style Type 1 Type 2 Type 3 Type 4 Type 5 Type All of the above frame styles and honeycomb combinations are available with the option of a stainless steel kick-plate Notice Information supplied in these data sheets is based on independent and laboratory tests which Kemtron believes to be reliable. Kemtron has no control over the design of customer s product which incorporates Kemtron s products, therefore it is the responsibility of the user to determine the suitability for his particular application and we recommend that the user make his own test to determine suitability. The product described in this data sheet shall be of standard quality, however the products are sold without warranty of fitness for a particular purpose, either expressed or implied, except to the extent expressly stated on Kemtron s invoice, quotation or order acknowledgement. Kemtron does not warrant that products described in this data sheet will be free of conflict with existing or future patents of third parties. All risks of lack of fitness, patent infringement and the like are assumed by the user. 103

104 Aluminium Honeycomb Air Ventilation Panels for RFI/EMI Shielding Technical Specifications 1701 Standard Frames Custom sizes and shapes available. Part Number Frame Outer Dimensions Open Area Open Area2 Number of Fixings Fixing Locations x0762-T4-K-TH-G X Y X1 Y1 cm2 in.2 X Y A B C D mm in. mm in. mm in. mm in. mm in. mm in. mm in. mm in x0762-XXX-X-XX-X x1016-XXX-X-XX-X x1016-XXX-X-XX-X x1270-XXX-X-XX-X x1016-XXX-X-XX-X x1270-XXX-X-XX-X x1524-XXX-X-XX-X x1016-XXX-X-XX-X x1524-XXX-X-XX-X x1778-XXX-X-XX-X x1270-XXX-X-XX-X x2032-XXX-X-XX-X x1778-XXX-X-XX-X x1524-XXX-X-XX-X x2032-XXX-X-XX-X x2032-XXX-X-XX-X x2540-XXX-X-XX-X x3048-XXX-X-XX-X Frames Part Number XX-X-XX-X Frame Style Overall outside dimensions Honeycomb type T4 = 2 layers 3.18 cell X 6.4mm thick oriented at 90º T6 = 1 layer 3.18 cell X 12.7mm thick Finishes K = Kempass S = Surtec 650 N = Nickel plate Fixings TH = through hole 5.5mm dia NO = no fixings M3, M4, M5, 8/32 = threaded inserts Gasket G = Monel knitted wire mesh with neoprene NG = no gasket 104

105 Aluminium Honeycomb Air Ventilation Panels for RFI/EMI Shielding Technical Specifications 1702 Standard Frames Custom sizes and shapes available. Part Number Frame Outer Dimensions Open Area Open Area2 Number of Fixings Fixing Locations x0762-T4-K-TH-G X Y X1 Y1 cm2 in.2 X Y A B C D mm in. mm in. mm in. mm in. mm in. mm in. mm in. mm in x0762-XXX-X-XX-G x1016-XXX-X-XX-G x1016-XXX-X-XX-G x1270-XXX-X-XX-G x1016-XXX-X-XX-G x1270-XXX-X-XX-G x1524-XXX-X-XX-G x1016-XXX-X-XX-G x1524-XXX-X-XX-G x1778-XXX-X-XX-G x1270-XXX-X-XX-G x2032-XXX-X-XX-G x1778-XXX-X-XX-G x1524-XXX-X-XX-G x2032-XXX-X-XX-G x2032-XXX-X-XX-G x2540-XXX-X-XX-G x3048-XXX-X-XX-G Frames Part Number XX-X-XX-X Frame Style Overall outside dimensions Honeycomb type T4 = 2 layers 3.18 cell X 6.4mm thick oriented at 90º T6 = 1 layer 3.18 cell X 12.7mm thick Finishes K = Kempass S = Surtec 650 N = Nickel plate Fixings TH = through hole 5.5mm dia NO = no fixings Gasket G = Monel knitted wire mesh 105

106 Aluminium Honeycomb Air Ventilation Panels for RFI/EMI Shielding Technical Specifications 1703 Standard Frames Custom sizes and shapes available. Part Number Frame Outer Dimensions Open Area Open Area2 Number of Fixings Fixing Locations x0762-T4-K-TH-G X Y X1 Y1 cm2 in.2 X Y A B C D mm in. mm in. mm in. mm in. mm in. mm in. mm in. mm in x0762-XXX-X-XX-G x1016-XXX-X-XX-G x1016-XXX-X-XX-G x1270-XXX-X-XX-G x1016-XXX-X-XX-G x1270-XXX-X-XX-G x1524-XXX-X-XX-G x1016-XXX-X-XX-G x1524-XXX-X-XX-G x1778-XXX-X-XX-G x1270-XXX-X-XX-G x2032-XXX-X-XX-G x1778-XXX-X-XX-G x1524-XXX-X-XX-G x2032-XXX-X-XX-G x2032-XXX-X-XX-G x2540-XXX-X-XX-G x3048-XXX-X-XX-G Frames Part Number XX-X-XX-X Frame Style Overall outside dimensions Honeycomb type T4 = 2 layers 3.18 cell X 6.4mm thick oriented at 90º T6 = 1 layer 3.18 cell X 12.7mm thick Finishes K = Kempass S = Surtec 650 N = Nickel plate Fixings TH = through hole 5.5mm dia NO = no fixings M3, M4, M5, 8/32 = threaded inserts Gasket G = Monel knitted wire mesh 106

107 Aluminium Honeycomb Air Ventilation Panels for RFI/EMI Shielding Technical Specifications 1704 Standard Frames Custom sizes and shapes available. Part Number Frame Outer Dimensions Open Area Open Area2 Number of Fixings Fixing Locations x0762-T4-K-TH-G X Y X1 Y1 cm2 in.2 X Y A B C D mm in. mm in. mm in. mm in. mm in. mm in. mm in. mm in x0762-XXX-X-XX-X x1016-XXX-X-XX-X x1016-XXX-X-XX-X x1270-XXX-X-XX-X x1016-XXX-X-XX-X x1270-XXX-X-XX-X x1524-XXX-X-XX-X x1016-XXX-X-XX-X x1524-XXX-X-XX-X x1778-XXX-X-XX-X x1270-XXX-X-XX-X x2032-XXX-X-XX-X x1778-XXX-X-XX-X x1524-XXX-X-XX-X x2032-XXX-X-XX-X x2032-XXX-X-XX-X x2540-XXX-X-XX-X x3048-XXX-X-XX-X Frames Part Number XX-X-XX-X Frame Style Overall outside dimensions Honeycomb type T4 = 2 layers 3.18 cell X 6.4mm thick oriented at 90º T6 = 1 layer 3.18 cell X 12.7mm thick Finishes K = Kempass S = Surtec 650 N = Nickel plate Fixings TH = through hole 5.5mm dia NO = no fixings Gasket G = Monel knitted wire mesh with neoprene NG = no gasket 107

108 Aluminium Honeycomb Air Ventilation Panels for RFI/EMI Shielding Technical Specifications 1705 Standard Frames Custom sizes and shapes available. Part Number Frame Outer Dimensions Open Area Open Area2 Number of Fixings Fixing Locations x0762-T4-K-TH-G X Y X1 Y1 cm2 in.2 X Y A B C D mm in. mm in. mm in. mm in. mm in. mm in. mm in. mm in x0762-XXX-X-XX-X x1016-XXX-X-XX-X x1016-XXX-X-XX-X x1270-XXX-X-XX-X x1016-XXX-X-XX-X x1270-XXX-X-XX-X x1524-XXX-X-XX-X x1016-XXX-X-XX-X x1524-XXX-X-XX-X x1778-XXX-X-XX-X x1270-XXX-X-XX-X x2032-XXX-X-XX-X x1778-XXX-X-XX-X x1524-XXX-X-XX-X x2032-XXX-X-XX-X x2032-XXX-X-XX-X x2540-XXX-X-XX-X x3048-XXX-X-XX-X Frames Part Number XX-X-XX-X Frame Style Overall outside dimensions Honeycomb type T1 = 2 layers 3.18 cell X 3.18mm thick oriented at 90 T2 = 1 layer 3.18 cell X 6.4mm thick T3 = 1 layer 1.60 cell X 6.4mm thick Finishes K = Kempass S = Surtec 650 N = Nickel plate Fixings TH = through hole 5.5mm dia NO = no fixings Gasket G = Monel knitted wire mesh with neoprene NG = no gasket 108

109 Aluminium Honeycomb Air Ventilation Panels for RFI/EMI Shielding Technical Specifications 1706 Standard Frames Custom sizes and shapes available. Part Number Frame Outer Dimensions Open Area Open Area2 Number of Fixings Fixing Locations x0762-T4-K-TH-G X Y X1 Y1 cm2 in.2 X Y A B C D mm in. mm in. mm in. mm in. mm in. mm in. mm in. mm in x0762-XXX-X-XX-X x1016-XXX-X-XX-X x1016-XXX-X-XX-X x1270-XXX-X-XX-X x1016-XXX-X-XX-X x1270-XXX-X-XX-X x1524-XXX-X-XX-X x1016-XXX-X-XX-X x1524-XXX-X-XX-X x1778-XXX-X-XX-X x1270-XXX-X-XX-X x2032-XXX-X-XX-X x1778-XXX-X-XX-X x1524-XXX-X-XX-X x2032-XXX-X-XX-X x2032-XXX-X-XX-X x2540-XXX-X-XX-X x3048-XXX-X-XX-X Frames Part Number XX-X-XX-X Frame Style Overall outside dimensions Honeycomb type T1 = 2 layers 3.18 cell X 3.18mm thick oriented at 90 T2 = 1 layer 3.18 cell X 6.4mm thick T3 = 1 layer 1.60 cell X 6.4mm thick Finishes K = Kempass S = Surtec 650 N = Nickel plate Fixings TH = through hole 5.5mm dia NO = no fixings Gasket G = Monel knitted wire mesh with neoprene NG = no gasket 109

110 Aluminium Honeycomb Air Ventilation Panels for RFI/EMI Shielding Technical Specifications 1707 Standard Frames Custom sizes and shapes available. Part Number Frame Outer Dimensions Open Area Open Area2 Number of Fixings Fixing Locations x0762-T4-K-TH-G X Y X1 Y1 cm2 in.2 X Y A B C D mm in. mm in. mm in. mm in. mm in. mm in. mm in. mm in x0762-XXX-X-XX-X x1016-XXX-X-XX-X x1016-XXX-X-XX-X x1270-XXX-X-XX-X x1016-XXX-X-XX-X x1270-XXX-X-XX-X x1524-XXX-X-XX-X x1016-XXX-X-XX-X x1524-XXX-X-XX-X x1778-XXX-X-XX-X x1270-XXX-X-XX-X x2032-XXX-X-XX-X x1778-XXX-X-XX-X x1524-XXX-X-XX-X x2032-XXX-X-XX-X x2032-XXX-X-XX-X x2540-XXX-X-XX-X x3048-XXX-X-XX-X Frames Part Number XX-X-XX-X Frame Style Overall outside dimensions Honeycomb type T4 = 2 layers 3.18 cell X 6.4mm thick oriented at 90º T6 = 1 layer 3.18 cell X 12.7mm thick Finishes K = Kempass S = Surtec 650 N = Nickel plate Fixings TH = through hole 5.5mm dia NO = no fixings M3 = threaded inserts Gasket G = Monel knitted wire mesh with neoprene NG = no gasket 110

111 Aluminium Honeycomb Air Ventilation Panels for RFI/EMI Shielding Technical Specifications 1709 Standard Frames Custom sizes and shapes available. Part Number Frame Outer Dimensions Open Area Open Area2 Number of Fixings Fixing Locations x0762-T4-K-TH-G X Y X1 Y1 cm2 in.2 X Y A B C D mm in. mm in. mm in. mm in. mm in. mm in. mm in. mm in x0762-XXX-X-XX-X x1016-XXX-X-XX-X x1016-XXX-X-XX-X x1270-XXX-X-XX-X x1016-XXX-X-XX-X x1270-XXX-X-XX-X x1524-XXX-X-XX-X x1016-XXX-X-XX-X x1524-XXX-X-XX-X x1778-XXX-X-XX-X x1270-XXX-X-XX-X x2032-XXX-X-XX-X x1778-XXX-X-XX-X x1524-XXX-X-XX-X x2032-XXX-X-XX-X x2032-XXX-X-XX-X x2540-XXX-X-XX-X x3048-XXX-X-XX-X Frames Part Number XX-X-XX-X Frame Style Overall outside dimensions Honeycomb type T2 = 1 layer 3.18 cell X 6.4mm thick T3 = 1 layer 1.60 cell X 12.7mm thick Finishes K = Kempass S = Surtec 650 N = Nickel plate Fixings TH = through hole 5.5mm dia NO = no fixings Gasket G = Monel knitted wire mesh with neoprene NG = no gasket 111

112 Aluminium Screen EMC and Dust Filter Ventilation Panels Product Overview Aluminium screen EMC & dust filter ventilation panels consist of multi-layer expanded aluminium foil mesh trapped in a rigid extruded aluminium mounting frame, the frame can be supplied in a choice of sizes and profiles. Panels can be treated with a variety of finishes to provide corrosion protection. Air filter oil can be applied to the aluminium filter media to assist in dirt and dust retention. Panels with a gasket groove have a knitted monel wire mesh gasket as standard. Other frames can be provided with an additional EMI Gasket. Applications Ventilation panels are designed for use in commercial electronic enclosures where air flow is required for cooling and ventilation but where EMC compliance and dust filtration must be ensured. Typical commercial applications are: Electronic Enclosures. Air Conditioning nits. an housings. EMC Racks. Availability A selection of aluminium, extruded profiles are available from stock offering a variety of fixing and Gasketing options. Custom sizes manufactured at no additional cost. Frames can be supplied with fixing holes to aid mounting. Aluminium screen EMC and dust filter ventilation panels can be supplied with a empass Ro S Aluminium passivation process finish. Design Considerations Any environmental conditions such as moisture and dust control including: Air low requirement enerally requires assisted air flow). External louvers for rain protection. Any additional asketing. Cleaning Vacuum or blow clean with an airline for dry panels or easily cleaned in detergent solution prior to re oiling. Constructional requirements and finishes including: Rigidity of vent frame and enclosure so as to prevent bowing of either surface when compressing the gasket. ixing requirements e.g. holes ensuring appropriate position and si e of hole-centres oles in the corners of the frame should be avoided). Corrosion electrical conductivity etc (see Finishes section). 112

113 Aluminium Screen EMC and Dust Filter Ventilation Panels Product Overview (Continued) Production Capabilities Kemtron manufacture its range of EMC vent panels using the latest technology and, with the exception of painting and electro less plating, all processes are kept in house, giving us flexibility and total control over quality. Kemtron has invested heavily in this area making us the market leaders for price, delivery, quality and availability. Fully programmable CNC machines for the notching & cutting of the frame extrusions and drilling of exact and repeatable holes combined with the latest TIG welding equipment allows Kemtron to offer a fast delivery of its competitive range of aluminium vent panels produced to customer designs. This advanced technology also eliminates the need for additional tooling and set-up charges. Kemtron holds a large range of aluminium extrusions. In addition to vent panels, Kemtron manufactures a huge range of EMI shielding products, including gaskets to compliment the vent panels. Finishes Vent panels can be supplied with a range of finishes including: ainted frame only for dust panels. Electro less plated in or Nickel. empass Ro S Aluminium assivation process. rivalent chromium Ro S compliant or exavalent chromium. Kemtron s standard finish (Kempass) for aluminium vent panels fully meets the Ro S directive and replaces Alocrom1200, which is a hexavalent chromium process. Kemtron s in-house process applies a permanganate passivation which is a chromate free, inorganic and non toxic coating. The process produces a dense, uniform coating consisting of aluminium and reduced manganese oxides giving a light yellow colour to the surface. The surface finish is conductive with a low contact resistance equalling Alocrom It also meets all requirements of MIL-C-5541E for corrosion and electrical conductivity. We are also able to offer a comprehensive range of painted finishes to complement our standard Kempass finish. Using industry leading wet paint solutions from Trimite, we offer full painting and preparation to DEF STAN specifications including matt and gloss finishes. In addition we can also offer Infra Red Re ecting IRR matt finishes complying with DEF STAN 00-23, and STANAG For less critical / commercial applications requiring a protected finish we recommend polyester powder coating. This is tough material that offers excellent resistance to fresh and saltwater, petrol, linseed and penetrating oils, along with limited resistance to various acids. We are happy to advise on specific examples if required. With both processes, we are able to offer a full range of colours to RAL S charts. 113

114 Aluminium Screen EMC and Dust Filter Ventilation Panels Technical Specifications Tolerances Standard tolerances for overall finished vent dimensions are +/- 0.8mm Standard tolerances on hole centres are +/- 0.4mm Specifications Aluminium frame 6063-T6 Monel wire BS3075 NA13 Air Flow Results Graph Pressure Drop (Pa) EMC Performance (db) Frequency. M. M. M. M M M M db Flow Speed (m/s) Frame Styles Notice Information supplied in these data sheets is based on independent and laboratory tests which Kemtron believes to be reliable. Kemtron has no control over the design of customer s product which incorporates Kemtron s products, therefore it is the responsibility of the user to determine the suitability for his particular application and we recommend that the user make his own test to determine suitability. The product described in this data sheet shall be of standard quality, however the products are sold without warranty of fitness for a particular purpose, either expressed or implied, except to the extent expressly stated on Kemtron s invoice, quotation or order acknowledgement. Kemtron does not warrant that products described in this data sheet will be free of conflict with existing or future patents of third parties. All risks of lack of fitness, patent infringement and the like are assumed by the user.

115 Combined EMC and Dust Filter Ventilation Panels Product Overview Aluminium EMC & dust filter ventilation panel consist of 3 layers of pleated aluminium woven mesh trapped between an expanded aluminium kick-plate then held in a rigid extruded aluminium mounting frame, The 3 layers of pleated wire mesh are separated by the pleats being of different height enabling the vent to have a high dust holding capacity. The vent panel can be used dry or air filter oil can be applied to the aluminium filter media to assist in dirt and dust retention. The frame can be supplied in a range of sizes and profiles and panels can be treated with a variety of finishes to provide corrosion protection or improve conductivity. Panels can be provided with additional EMI gasketing or environmental sealing if required. Applications Ventilation panels are designed for use in electronic enclosures where good air flow is required for cooling and ventilation but where EMC compliance and dust filtration must be ensured. Typical commercial applications are: Electronic Enclosures. Air Conditioning nits. an housings. EMC Racks. Availability A large selection of Aluminium, extruded profiles are available from stock offering a variety of fixing and gasketing options. Custom sizes manufactured with no additional cost. Frames can be supplied with fixing holes or captive threaded inserts to aid mounting. These ventilation panels can be supplied with a Kempass Ro S Aluminium passivation nish. Design Considerations Any environmental conditions such as moisture and dust control including Air low requirement enerally requires assisted air flow). External louvers for rain protection. rain holes. Any additional gasketing. Cleaning Vacuum or blow clean with an airline for dry panels or easily cleaned in detergent solution prior to re oiling. Constructional requirements and finishes including Rigidity of vent frame and enclosure so as to prevent bowing of either surface when compressing the gasket Fixing requirements e.g. holes or threaded inserts ensuring appropriate position and size of hole-centres. oles in the corners of the frame should be avoided. If specifying captive inserts in both sides of the frame off-set the positions by 10mm minimum. Round vents tend to be an expensive option due to the complexity of manufacturing method. 115

116 Combined EMC and Dust Filter Ventilation Panels Product Overview (Continued) Gaskets for vents nitted wire mesh rames with a gasket groove. rientated wire in silicone. nitted Monel wire mesh with a Neoprene sponge carrier 2.4mm thick. eryllium Copper nger stock. ther gasket options are available Production Capabilities Kemtron manufacture its range of EMC vent panels using the latest technology and, with the exception of painting and plating, all processes are kept in house, giving us flexibility and total control over quality. Kemtron has invested heavily in this area making us the market leaders for price, delivery, quality and availability. ully programmable CNC machines for the notching cutting of the frame extrusions and drilling of exact and repeatable holes combined with the latest I welding equipment allows Kemtron to offer a fast delivery of its competitive range of aluminium woven mesh produced to customer designs. This advanced technology also eliminates the need for additional tooling and set-up charges. Kemtron holds a large range of aluminium extrusions and aluminium woven mesh in stock. In addition to vent panels, Kemtron manufactures a huge range of EMI shielding products, including conductive Elastomers, oriented wire, knitted wire mesh, connector gaskets. Vent panels made with styles 1701, 1703, are supplied with 3 corners notched and the 4th joined corner welded and have an external corner radii of 3mm. Finishes Vent panels can be supplied with a range of finishes including: ainted frame only for dust panels. Electro less plated in or Nickel. empass Ro S Aluminium assivation process. rivalent chromium Ro S compliant or exavalent chromium. Kemtron s standard finish (KEM-PAS) for aluminium vent panels fully meets the Ro S directive and replaces Alocrom1200, which is a hexavalent chromium process. Kemtron s in-house process applies a permanganate passivation which is a chromate free, inorganic and non toxic coating. The process produces a dense, uniform coating consisting of aluminium and reduced manganese oxides giving a light yellow colour to the surface. The surface finish is conductive with a low contact resistance equalling Alocrom It also meets all requirements of MIL-C-5541E for corrosion and electrical conductivity. We are also able to offer a comprehensive range of painted finishes to complement our standard Kempass finish. Using industry leading wet paint solutions from Trimite, we offer full painting and preparation to DEF S AN speci cations including matt and gloss nishes. In addition we can also offer Infra Red Re ecting IRR matt nishes complying with E S AN - - and S ANA. For less critical / commercial applications requiring a protected finish we recommend polyester powder coating. This is tough material that offers excellent resistance to fresh and saltwater, petrol, linseed and penetrating oils, along with limited resistance to various acids. We are happy to advise on specific examples if required. With both processes, we are able to offer a full range of colours to RAL S charts. 116

117 Combined EMC and Dust Filter Ventilation Panels Technical Specifications Tolerances Standard tolerances for overall finished vent dimensions are +/- 0.8mm Standard tolerances on hole centres are +/- 0.4mm Typical corner radii on frame styles 1701 and 1703 are R. mm 1702 Specifications Aluminium frame 6063-T6 Aluminium filter material wire dia 0.28mm open area 66% Monel wire gasket S NA Neoprene sponge AS M SCE Beryllium copper alloy 25 (CA172) Silicone rubber -R- Class rade Aluminium wire Air Flow Results Graph Pressure Drop (Pa) 1704 Flow Speed (m/s) EMC Performance (db) 1710 Frequency. M. M. M. M M M M db Frame Styles 1701 Notice Information supplied in these data sheets is based on independent and laboratory tests which Kemtron believes to be reliable. Kemtron has no control over the design of customer s product which incorporates Kemtron s products, therefore it is the responsibility of the user to determine the suitability for his particular application and we recommend that the user make his own test to determine suitability. The product described in this data sheet shall be of standard quality, however the products are sold without warranty of fitness for a particular purpose, either expressed or implied, except to the extent expressly stated on Kemtron s invoice, quotation or order acknowledgement. Kemtron does not warrant that products described in this data sheet will be free of conflict with existing or future patents of third parties. All risks of lack of fitness, patent infringement and the like are assumed by the user. 117

118 EMP Honeycomb Ventilation Panels Product Overview Steel honeycomb air ventilation panels are designed for high performance applications, where high attenuation is required particularly in the H (magnetic) field. Steel honeycomb air ventilation panels consist of a steel honeycomb foil soldered in to a rigid mounting frame. The steel foil is formed and laminated into a series of honeycomb cells that are welded at the join, ensuring a conductive path at each join. The frame can be supplied with an integral or separate EMI/RFI gasket, and can be treated with a variety of finishes to provide corrosion protection or improve conductivity. Applications Ventilation panels are designed for use in electronic enclosures where good air flow is required for cooling and ventilation but where EMC compliance must be ensured. Typical applications are: Screened Rooms. Military Air Conditioning nits. igh performance Communication shelters. EM installations. Availability All panels are individually built to your speci cation Size, Honeycomb configuration, frame style, fixing method and finish. Frames can be supplied with fixing holes to aid mounting. Design Considerations Any environmental conditions such as moisture and dust control including Air low requirement. External louvres for rain protection. rain holes. Any additional gasketing. Constructional requirements and finishes including Rigidity of vent frame and enclosure. ixing options e.g. holes Soldering. ype of gasket if required. rame style. Corrosion electrical conductivity etc (see Finishes section). Finishes Vent panels are supplied with a standard finish of hot tin dipped. However an additional coating is recommended to help combat corrosion. We can advise on a number of painted finishes. 118

119 EMP Honeycomb Ventilation Panels Product Overview (Continued) Production Capabilities Kemtron manufacture its range of EMC vent panels using the latest technology and, with the exception of painting and electro less plating, all processes are kept in house, giving us flexibility and total control over quality. Kemtron has invested heavily in this area making us the market leaders for price, delivery, quality and availability. In addition to vent panels, Kemtron manufactures a huge range of EMI shielding products, including conductive elastomers, oriented wire, knitted wire mesh, connector gaskets. Tolerances Standard tolerances for overall finished vent dimensions are +/- 0.8mm Standard tolerances on hole centres are +/- 0.4mm Finishes Vent panels can be supplied with a range of finishes including: ainted. Electro less plated in or Nickel. ot tin dipped. We are also able to offer a comprehensive range of painted finishes to complement our standard finish. Using industry leading wet paint solutions from Trimite, we offer full painting and preparation to E S AN specifications including matt and gloss finishes. In addition we can also offer Infra Red Reflecting (IRR) matt nishes complying with E S AN - - and S ANA. For less critical / commercial applications requiring a protected finish we recommend polyester powder coating. This is tough material that offers excellent resistance to fresh and saltwater, petrol, linseed and penetrating oils, along with limited resistance to various acids. We are happy to advise on specific examples if required. As the epoxy process is an electrostatic method, it offers excellent penetration of the honeycomb cells, further aiding resistance to corrosion. With both processes, we are able to offer a full range of colours to RAL S charts. Notice Information supplied in these data sheets is based on independent and laboratory tests which Kemtron believes to be reliable. Kemtron has no control over the design of customer s product which incorporates Kemtron s products, therefore it is the responsibility of the user to determine the suitability for his particular application and we recommend that the user make his own test to determine suitability. The product described in this data sheet shall be of standard quality, however the products are sold without warranty of fitness for a particular purpose, either expressed or implied, except to the extent expressly stated on Kemtron s invoice, quotation or order acknowledgement. Kemtron does not warrant that products described in this data sheet will be free of conflict with existing or future patents of third parties. All risks of lack of tness patent infringement and the like are assumed by the user. 119

120 EMI Shielded Windows Product Overview Shielded windows provide a high performance EMI shield while maintaining optimum optical transparency. Screening or shielding of optical windows is achieved by using either: A very ne woven wire mesh trapped between or embedded in a clear optical substrate such as acrylic, polycarbonate or glass, or A transparent vapour deposited conductive coating such as Indium in xide or Gold applied to the surface of the clear optical substrate. ermination of the window to the enclosure is achieved with a continuous low resistance conductive edge around the window, either a conductive buss bar and conductive gasket, or extended wire mesh see window mounting Application EMI shielded windows provide an EMI screen as part of a shielded enclosure which will provide protection against radiated emissions and susceptibility. Shielded windows provide good transparency for viewing display devices such as LE LC vacuum fluorescent, plasma etc and they can also form the front panel of an enclosure to provide impact protection, contrast enhancement of displays, display colour matching, anti reflection and an anti glare surfaces. Large windows can provide transparent EMI shielding for architectural use such as computer rooms, shielded rooms, MRI rooms and secure communication cabins. Availability EMI shielded windows are made to customer speci cation. Si es can range from cm up to x metres for architectural use. indows can be silk screened or printed with logos, information etc. ermination can be by mechanical clamping using a conductive gasket or by bonding into the enclosure with a conductive adhesive. 120 Notice Information supplied in these data sheets is based on independent and laboratory tests which emtron believes to be reliable. emtron has no control over the design of customer s product which incorporates emtron s products therefore it is the responsibility of the user to determine the suitability for his particular application and we recommend that the user make his own test to determine suitability. he product described in this data sheet shall be of standard quality however the products are sold without warranty of tness for a particular purpose either expressed or implied except to the extent expressly stated on emtron s invoice quotation or order acknowledgement. emtron does not warrant that products described in this data sheet will be free of con ict with existing or future patents of third parties. All risks of lack of tness patent infringement and the like are assumed by the user. - inch rive Springwood Industrial Estate raintree Essex CM S nited ingdom. T F E info@kemtron.co.uk,

121 EMI Shielded Windows Product Overview (Continued) Design Considerations Optical Substrates Acrylic is a versatile substrate available in a range of colours to match display outputs to improve contrast enhancement including clear which exhibits light transmission through to infra-red transmitting opaque materials. Acrylic is easily machined and formed making it suitable for front panels needing cut outs, holes, steps etc. Multiple layers can be fully laminated with ne wire meshes together with different colour combinations and the inclusion of circular polari ers. Acrylic has a L ammability rating and hard anti scratch, chemical resistant coatings can be applied to the surface as an optical flat or as anti-glare. Polycarbonate has very high impact resistance, more than times that of Acrylic and times more than glass making it most suitable for rugged applications. Whilst its light transmission is not as good as other substrates at it has the advantage of having L V ammability rating over. mm thickness. ard anti scratch chemical resistant coatings can be applied to the surface as an optical flat or as anti-glare. Fine wire meshes can be fully laminated between two layers. Glass has a very durable surface and will withstand high temperatures making it suitable for the application of vapour coatings such as I indium tin oxide for EMI shielding and/or anti reflection coatings that will reduce rst surface re ections to less than.. lass can be fully laminated with ne wire meshes and circular polari ers when required. ADC (Allyl Diglycol Carbonate) trade name CR has a very hard surface hence its use as spectacle lenses. A C is normally cast and has good impact resistance and is highly formable but is easily broken if scratched or notched. A C meets L ammability rating but is the most expensive substrate. Shielding Media Fine Wire Meshes provide the highest level of shielding while maintaining excellent optical properties. Wires used as the EMI shield are stainless steel or copper. he stainless steel mesh ranges from wires per inch up to copper mesh and. ire diameters are. mm or. mm for stainless. mm for copper. he greater wire density gives better shielding performance but light transmission and optical clarity is degraded. he optimum wire count to achieve good shielding and optical characteristics is around - wires per inch. he wire is plated and blackened to fuse the wire crossovers ensuring consistent EMC performance and the blackening reduces specular reflection from the mesh, enhancing the optics. Wire meshes can cause moir fringing on some displays. o eliminate this the wire is orientated in the substrate at an angle to be determined during the window design, this may from to degrees dependant on the display. Transparent Vapour Deposited Conductive Coatings I indium tin oxide and old can be applied to the substrates but do not provide as effective shielding as the wire meshes. heir advantage is that optical clarity is maintained and there is no degradation in resolution or fringing that can be caused by ne wire meshes. he coating can be applied in various thicknesses to achieve a resistance of or ohms square. - inch rive Springwood Industrial Estate raintree Essex CM S nited ingdom. T F E info@kemtron.co.uk, 121

122 EMI Shielded Windows Design Considerations (Continued) Extended wire Conductive edge only buss Wire mesh extends to edge of panel Combination conductive and environmental gasket Conductive Z buss Conductive U buss Wire mesh extends to edge of panel Conductive gasket Conductive L buss Wire mesh extends to edge of panel inch rive Springwood Industrial Estate raintree Essex CM S nited ingdom. T F E info@kemtron.co.uk,

123 EMI Shielded Windows Technical Specifications Shielding Effectiveness Stainless Steel Wire Mesh Stainless steel wire Silver plated fusing the wire crossovers and blackened with a black corrosion resistant plating mesh type stainless steel with a. wire diameter mesh type stainless steel with a. wire diameter mesh type stainless steel with a. wire diameter ort si e x test performed in accordance with NSA - and MIL-S - H Field Frequency d d d d d d d M d d d E Field Frequency d d d d d d d M db d d M d E Field & Plane Wave Frequency d Plane Wave Frequency M d d M d d M d d M d M d M d M d M d d d d d d d d d d d d Copper Wire Meshes lated fusing the wire crossovers and blackened with a black corrosion resistant plating mesh type with a. wire diameter ort si e x test performed in accordance with NSA - and MIL-S - H Field Frequency 1 d d M d E Field Frequency 1 d d d M d M d Plane Wave Frequency 1 M d M d M d M d M d M d d d d db E Field & Plane Wave Frequency 1 M d - inch rive Springwood Industrial Estate raintree Essex CM S nited ingdom. T F E info@kemtron.co.uk, 123

124 EMI Shielding Cable Glands Product Overview EMI cable glands are manufactured in brass and consist of 4 parts. The body, cap, locknut and the mesh olive. The cable entry gland uses a wire mesh olive, which consists of knitted wire mesh over a silicone core which when compressed by the cap being tightened to the body provides circumferential pressure to both the cable and gland body, giving excellent electrical conductivity between the two. Application The Cable Entry Gland provides an excellent EMP/RFI/EMI shield for screened cable which pass through enclosure walls. Availability Manufactured in a range of sizes to accommodate cables with a diameter over the screen from 2mm up to 16mm Design Considerations A round or threaded hole is required to mount the gland. (The gland can also be soldered into the enclosure wall). Using a heat shrink boot (not supplied) can also provide a degree of environmental sealing. Production Capabilities Kemtron manufacture these glands as a standard part, however if you require something slightly different or with a plated finish we are able to accommodate requests subject to minimum quantities. Part No. Max Ø over screen Min Ø over screen Dim A Dim B Dim C Hole Ø Thread mm 1.5mm 15mm 7mm 15mm 10.5mm M mm 4.0mm 17mm 7mm 18mm 12.5mm M mm 6.0mm 20mm 8mm 22mm 16.5mm M mm 7.5mm 20mm 8mm 24mm 20.5mm M mm 12.0mm 25mm 9mm 30mm 26.0mm M25 124

125 EMI Shielding Cable Glands Technical Specification Typical Shielding Performance Profile H Field MHz Attenuation (db) E Field MHz Attenuation (db) >130 >128 >120 >120 Materials Brass Body BS2870 EMC Gasket Kemtron 525 material (Silicone ZZ-R-765 Class2 GR50-60ºC TO 200ºC Woven Aluminium: AMS 4182) Knitted Wire Mesh Tin Plated Copper Clad Steel (TCS): Wire diameter 0.11mm UK Specification BS2316*, BS4087* USA Specification ASTM B277*, ASTM B452*, ASTM B520, ASTM B33*, AISI 1010 * There is no complete specification for this material. Processes have been derived from parts of the above where applicable. Silicone Ring ZZ-R-765 2b 40-60ºC TO 200ºC Notice Information supplied in these data sheets is based on independent and laboratory tests which Kemtron believes to be reliable. Kemtron has no control over the design of customer s product which incorporates Kemtron s products, therefore it is the responsibility of the user to determine the suitability for his particular application and we recommend that the user make his own test to determine suitability. The product described in this data sheet shall be of standard quality, however the products are sold without warranty of fitness for a particular purpose, either expressed or implied, except to the extent expressly stated on Kemtron s invoice, quotation or order acknowledgement. Kemtron does not warrant that products described in this data sheet will be free of conflict with existing or future patents of third parties. All risks of lack of fitness, patent infringement and the like are assumed by the user. 125

126 Cable Shielding Jackets Product Overview Kemzip is a cable screening product designed to be wrapped around cables requiring EMI/EMC protection. It is especially suitable for retrofitting to products already in production that are suffering from RFI radiation or conducted emission susceptibility problems. UV, ozone and weather resistant, self-extinguishing materials operating over a minimum temperature range of -30 C to +105 C. Kemzip is available in many variants, contact us to discuss your specific application, see below for examples of some of the range. 126 Notice Information supplied in these data sheets is based on independent and laboratory tests which Kemtron believes to be reliable. Kemtron has no control over the design of customer s product which incorporates Kemtron s products, therefore it is the responsibility of the user to determine the suitability for his particular application and we recommend that the user make his own test to determine suitability. The product described in this data sheet shall be of standard quality, however the products are sold without warranty of fitness for a particular purpose, either expressed or implied, except to the extent expressly stated on Kemtron s invoice, quotation or order acknowledgement. Kemtron does not warrant that products described in this data sheet will be free of conflict with existing or future patents of third parties. All risks of lack of fitness, patent infringement and the like are assumed by the user.

127 Cable Shielding Jackets Technical Specifications SH1/63 Zip-on light weight tubing especially for ribbon cables. Jacket material is laminated to aluminium foil to provide full EMI shielding. Tinned copper grounding braid is attached to inside overlap for termination. SH/CC Light weight EMI shielding designed especially for applications where high flexibility is required. Basic material is PVC-GPs with Ni/Cu polyester cloth. Closing systems: Z or F Closing systems: Z SHX 2/4 Example of closing systems types Z, F & N : Highly flexible EMI shielding and protection. Knittedwire mesh in 2-ply material with tinned copper braid attached to inside overlap provides seal and solderable termination point. Closing systems: Z, F or N (N from 16mm). Typical attenuation (db) of Kemzip materials Freq. SH1/63 SH/CC SHX2 SHX4 10 Mhz Mhz Mhz Mhz Mhz Ghz Ghz Ghz

128 Conductive Adhesive Tapes Product Overview Electrically conductive foil tape is manufactured by applying a conductive adhesive to one or both surfaces of a metal foil such as copper or aluminium. This is then either self wound or has a separate release liner applied. This is then slit to standard or custom widths. Applications emporary sealing of gaps for EMC testing. C shields. Cable shields. Shielded room seams. Availability Normally supplied in 33 metre rolls, in standard widths of 13mm & 25mm. However any width from 8mm up to approx 200mm, and 50 metre rolls can be supplied to special order. We can also supply with non-conductive adhesive or without adhesive if required, to special order. Tapes can be supplied in two versions Self Wound, without a release liner, or with a paper release liner. Versions having the paper release liner have a suffix -6 added to the part number. Example Copper Tape with conductive adhesive with release liner = without release liner = 9115 Design Considerations Consider if it is a temporary or permanent solution. alvanic compatibility. Adhesive strength. Production Capabilities ie cutting. Slitting. Laminating. Material Part No Aluminium Tape with conductive adhesive for EMI shielding Copper Tape with non-conductive adhesive Copper Tape with conductive adhesive for EMI shielding, solderable Copper Tape with conductive adhesive on both sides for EMI shielding Tin-clad Copper Tape with non-conductive adhesive, solderable Tin-clad Copper Tape with conductive adhesive, solderable ie cut parts iss cut parts Notice Information supplied in these data sheets is based on independent and laboratory tests which Kemtron believes to be reliable. Kemtron has no control over the design of customer s product which incorporates Kemtron s products, therefore it is the responsibility of the user to determine the suitability for his particular application and we recommend that the user make his own test to determine suitability. The product described in this data sheet shall be of standard quality, however the products are sold without warranty of fitness for a particular purpose, either expressed or implied, except to the extent expressly stated on Kemtron s invoice, quotation or order acknowledgement. Kemtron does not warrant that products described in this data sheet will be free of conflict with existing or future patents of third parties. All risks of lack of fitness, patent infringement and the like are assumed by the user.

129 Conductive Adhesive Tapes Technical Specification Materials 9015: Aluminium Tape with Conductive Adhesive for EMI Shielding Stocked in 25mm widths. Base thickness Total thickness Adhesive strength Tensile strength 0.040mm 0.065mm 4.5 N/cm 25 N/cm Temperature resistance 155 C Electrical resistance through adhesive* Ohms 9116: Copper Tape with Conductive Adhesive on both sides for EMI Shielding ** Special order only Base thickness Total thickness Adhesive strength Tensile strength 0.035mm 0.085mm 4.5 N/cm 55 N/cm Temperature resistance 155 C Electrical resistance through adhesive* Ohms 9110: Copper Tape with Non-Conductive Adhesive ** Special order only Base thickness Total thickness Adhesive strength Tensile strength 0.035mm 0.070mm 4.5 N/cm 55 N/cm Temperature resistance 155 C 9115: Copper Tape with Conductive Adhesive for EMI Shielding, Solderable Stocked in 13mm & 25mm width. Base thickness Total thickness Adhesive strength Tensile strength 0.035mm 0.060mm 4.5 N/cm 55 N/cm Temperature resistance 155 C Electrical resistance through adhesive* Ohms 9510: Tin-clad Copper Tape with Non-Conductive Adhesive, Solderable ** Special order only Base thickness Total thickness Adhesive strength Tensile strength 9515: Tin-clad Copper Tape with Conductive Adhesive, Solderable ** Special order only Base thickness Total thickness Adhesive strength Tensile strength 0.035mm 0.060mm 4.5 N/cm 40 N/cm 0.035mm 0.060mm 4.5 N/cm 40 N/cm Temperature resistance 155 C Temperature resistance 155 C Electrical resistance through adhesive* Ohms Shielding Effectiveness 20MHz 100MHz 500MHz 1GHz 62.5dB 54dB 55dB 52.5dB Shielding Effectiveness 20MHz 100MHz 500MHz 1GHz 62.5dB 58.5dB 50dB 61.5dB Electrical resistance tested according to MIL S Method across surface area of 25.4 sq mm Conductive foil tape 129

130 EMI Shielding Laminates 130 Product Overview Custom designed shielding laminates are manufactured with electrically conductive metal foil laminated to another substrate often a nonconductive material such as melinex. The conductive media can be insulated across the whole surface or selective areas. This can then be made self adhesive backed. Application A unique range of laminated shields applying selective die cutting techniques for cost effective solutions to a variety of shielding problems. Available in a wide range of materials and thicknesses. Shielding laminates are commonly provide a removable RFI / EMI shield in PCB housings, key board, touch panel shields and for isolating components in electronic enclosures. Availability Bespoke Laminates can be produced quickly to suit particular applications and provide a more effective solution than a standard product. Die cutting is a flexible process offering a cost effective product with quick turn round times. Lower cost than conductive coatings. Effective attenuation. Recyclability. Lower tooling and set up costs. Insulating capabilities. Scratch resistant. Short lead times. Easy prototyping. Design Considerations Factors such as size, volume, accessibility of components etc will dictate the design suited to a particular application but careful consideration should be given when choosing the required material: Production Capabilities Kemtron has considerable experience in the design, manufacture of a wide range of shielding products and is able to help customers find solutions to their shielding requirements. Specifications As laminates are custom designed please contact our sales department to discuss your requirements. We will need a drawing or specification giving overall dimensions, type of material configurations, quantity, tolerances, packaging and any special requirements. Notice Information supplied in these data sheets is based on independent and laboratory tests which Kemtron believes to be reliable. Kemtron has no control over the design of customer s product which incorporates Kemtron s products, therefore it is the responsibility of the user to determine the suitability for his particular application and we recommend that the user make his own test to determine suitability. The product described in this data sheet shall be of standard quality, however the products are sold without warranty of fitness for a particular purpose, either expressed or implied, except to the extent expressly stated on Kemtron s invoice, quotation or order acknowledgement. Kemtron does not warrant that products described in this data sheet will be free of conflict with existing or future patents of third parties. All risks of lack of fitness, patent infringement and the like are assumed by the user.

131 EMI Shielding Laminates Technical Specifications Adhesives & Foils Adhesive Thickness Foil Material Standard Thicknesses Acrylic Copper to Tin Plated Copper to Aluminium to Rubber Stainless Steel to Conductive Insulating Substrates Material Trade name Thickness UL Fire Rating Max. Width Polyester Mylar to VTM-2 72 Polycarbonate Lexan to V-2 to 94V-0 48 Polypropylene Formex / to VTM-0 to 94V-0 24 Statex Polyvinylchloride to HB to 94V-0 54 Polyamide Nomex to V-0 36 PBTP Valox to VTM-0 to 94V-0 48 Polyimide Kapton to V

132 Board Level Shielding Cans Product Overview Custom designed shielding cans are manufactured by photo etching or pressing thin metal sheet, which is then folded and soldered or tabbed to form the shielding can. Cans can have a removable or a fixed integral lid and they are then mounted on a PCB covering single or multiple components to provide excellent EMI/RFI shielding. Application PC board screening cans present an effective solution to the isolation of board level components and can provide individual or multi-cavity shielding over components on a PCB. Availability Bespoke cans can be produced quickly to suit particular applications and provide a more effective solution than a standard product. Photo Etching is a flexible process offering a cost effective product with quick turn round times. Cans be supplied flat for self folding with etched fold lines or ready folded. Stamping and pressing is a more expensive process due to tooling costs but offers high volume capability with low unit costs and are only available ready folded Cans be produced with solid tops or with removable fingered lids for component access. Cans can be supplied to suit through hole or surface mount assembly. Internal dividers can be added to most designs. Ventilation and access holes can be incorporated in both lids and fences. Smaller cans can be supplied tape and reeled for automated assembly. A wide range of materials and nishes are available including non ferrous metals such as phosphor-bronze and beryllium copper and tin, nickel and tin/lead plating finishes. Design Considerations Factors such as size, volume, assembly technique, accessibility of components etc will dictate the design suited to a particular application but careful consideration should be given when choosing the required material: Low frequency applications such as transformers coils etc should use a high permeability material such as steel or nickel iron. igh frequency applications such as microprocessors fast switching devices, switched mode power supplies should use non-ferrous materials. Production Capabilities Kemtron has considerable experience in the design, manufacture and testing of a wide range of shielding products and is able to help customers find solutions to their shielding requirements. Specifications As cans are custom designed please contact our sales department to discuss your requirements. We will need a drawing or specification giving overall dimensions, type of material, plating, through hole/surface mount configurations, quantity, tolerances, packaging and any special requirements. 132

133 Ferrites for EMI Suppression Product Overview Kemtron distribute a large range of ferrites for EMI suppression. Our warehouse facility has a large range of cable and surface mount products which are generally available for same day despatch. Non stocked parts can also be obtained in a few working days. Kemtron distributes from world leading producers of ferrite and related materials used in the electronics, copier, telecomms, military and automotive industries. Nickel zinc ferrite parts are used extensively in the suppression of electromagnetic interference commonly known as EMI Ferrite, materials exhibit magnetic properties which are dependent on the frequency at which they are excited. In electronic applications the relation of the magnetic loss to frequency is utilized to attenuate interference frequencies where the material s losses are high, yet pass the lower bands where data is carried. The Kemtron range of EMI ferrite is split into two main areas: Cable ferrites comprising solid and split core versions for use on round and ribbon type cables. Broadband & High Frequency versions are now available for round and cylindrical cores. oard Mount roducts comprising chip ferrites common mode chokes multi-turn devices etc, many available in both surface mount and through hole board versions. The ranges are extensive and continually being updated, please visit our web site to view the range or contact our sales office to discuss your requirements. - inch rive Springwood Industrial Estate raintree Essex CM S nited ingdom. T F E info@kemtron.co.uk, 133

134 Environmental Sealing Overview Product Overview Kemtron offers a wide range of products designed for all areas of environmental sealing for electronic instruments, cabinets and enclosures from flat gaskets, extrusions, O rings and form in place. We are able to offer materials that have wide temperature ratings, long operational life, IP sealing, resistance to fluids and NBC chemicals, UL94 listings for fire retardancy, low toxicity products etc, many available from stock. Kemtron can offer precision cutting, slitting, kiss-cutting, extrusions, mouldings, form in place dispensing direct to surfaces and a comprehensive range of vulcanized silicone O rings. Kemtron has full facilities available to self-adhesive back materials, provide integral compression stops or collars to prevent gasket damage and fabrication of gaskets, etc. 134

135 Environmental Sealing Flat Gaskets Product Overview Kemtron has the capability to produce many designs and styles of flat gaskets. We have a versatile process of manufacture, which is ideally suited for development and pre-production through to full production volumes. Modern tooling, enable complex shapes to be produced whilst maintaining tight, repeatable tolerances. Single or multipart tool configurations allow for efficient, economical production techniques. Flat gaskets are produced from sheet while larger gaskets can be cut from fabricated picture frames. This option has the advantage of saving material and allows larger gaskets to be produced economically. This is facilitated by our in-house tool making and silicone moulding facilities. Fabricated frames use either extruded or moulded flat section that is joined by vulcanizing the polymer. This process has allowed Kemtron to produce gaskets up to 2 meters long, with the same mechanical integrity as is found in a single part gasket cut from sheet. This method of manufacture often offers cost savings over cutting from sheet with subsequent loss of waste material. During this process compression stops or collars can also be incorporated. This leads to reduced hardware costs and negates the need for fixings to be torqued to prevent over compression and damage to the gasket. Our experience in laminating allows us to apply self-adhesive backing tape to even the most difficult materials such as silicone, regardless of quantities. We use a range of high performance tapes suitable for all conditions. Kemtron has in house slitting capability, which allows us to convert sheet or log materials into strip or coils. This flexible technique with short lead times allows materials to be supplied to exact customer requirements with low minimum order quantities. 135

136 Environmental Sealing Flat Gaskets Product Overview Availability Continuous lengths up to mtrs long for slit coils. abricated gaskets to customer s drawings. Can be tted with compression limit stops or collars. Easily assembled using the self-adhesive backing option. (Self-adhesive backing is an assembly aid only). A broad range of si es available. A large range of materials to suit many climatic conditions. Large fabricated gaskets can be produced economically. L ame retardant approved materials are also available. Design Considerations It is important that this material is not overcompressed. If the design of the equipment does not allow for any mechanical method of preventing over-compression, the gasket should be fitted with built-in compression limiters, either metal stops fitted to the gasket, or metal collars fitted into each fixing hole. hen specifying die cut gaskets minimum material width should not be less than 2mm or at least the material thickness in any part of the gasket. If this cannot be achieved around fixing holes consider using a slot. Particular attention is required if specifying compression collars in holes. articular consideration must be given to compression forces, hole centres, size and number of fixings and rigidity of mating flanges. Compression 3 Compression Limit Applications Limit Collars 10mm 10mm Limit Stops Min Dia 3mm Horse Shoe Slot Insufficient land Horseshoe slot Notice Information supplied in these data sheets is based on independent and laboratory tests which Kemtron believes to be reliable. emtron has no control over the design of customer s product which incorporates emtron s products therefore it is the responsibility of the user to determine the suitability for his particular application and we recommend that the user make his own test to determine suitability. The product described in this data sheet shall be of standard quality, however the products are sold without warranty of fitness for a particular purpose, either expressed or implied, except to the extent expressly stated on emtron s invoice quotation or order acknowledgement. Kemtron does not warrant that products described in this data sheet will be free of conflict with existing or future patents of third parties. All risks of lack of tness patent infringement and the like are assumed by the user. Minimum Land 136 *special minimum order quantity may apply 2mm min land area (or thickness of material if over 2mm)

137 Environmental Sealing Flat Gaskets Technical Specification Silicone Sponge SP16 Width (mm) Temperature Range Density Colour Flame Kg M 3 Resistance Closed Cell C/+200 C 250 White None Thickness 1.5mm, 2.5mm, 3.0mm, 4.0mm, 5.0mm, 6.0mm, 8.0mm, 9.5mm, 12.5mm SP16VO Width (mm) Temperature Range Density Colour Flame Kg M 3 Resistance Closed Cell C/+200 C 200 Grey L V Thickness 1.5mm, 2.5mm, 3.0mm, 5.0mm, 6.0mm Rogers Bisco Silicone Sponge BF1000 Width (mm) Temperature Range Density Colour Flame Kg M 3 Resistance Open Cell C/+200 C 192 White L V Thickness 1.6mm, 2.4mm, 3.2mm, 4.8mm, 6.4mm HT800 Width (mm) Temperature Range Density Colour Flame Kg M 3 Resistance Closed Cell C/+200 C 192 Grey L V Thickness 1.6mm, 2.4mm, 3.2mm, 4.8mm, 6.4mm Solid Silicone General Purpose Thickness Width (mm) Temperature Range Hardness Shore Colour* Flame Resistance C/+200 C 40 or 60 T/B/W None 0.5mm, 0.8mm, 1.0mm, 1.5mm, 2.0mm, 2.5mm, 3.0mm Closed Cell Expanded Chloropene Sponge (Neoprene Sponge) Grade Width (mm) Temperature Range Average Density Kg M 3 Colour Flame Resistance Medium C/+80 C 120 Black Self- Extinguishing Firm C/+80 C 140 Black Self- Extinguishing Thickness 1.5mm, 2.5mm, 3.0mm, 4.0mm, 5.0mm, 6.0mm, 8.0mm, 10.0mm Rogers Poron Grade Width (mm) Temperature Range Density Colour Flame Kg M 3 Resistance C/+90 C Black L C/+90 C Black L Thickness 0.8mm, 1.6mm, 2.4mm, 3.2mm, 4.8mm, 6.4mm Tolerance Gaskets Finished gaskets +/-0.8mm up to 300mm +/-1.2mm over 300mm ole centres -. mm Material thickness Up to 2.0mm thickness ± 0.5mm 2.0mm to 10.0mm thickness ± 0.8mm Above mm thickness. mm *Colour: T=Translucent B=Black W=White Please enquire as to the stock colour as a minimum quantity may apply. Other shore hardness sheets and colour options are available from our own compounding and moulding Facility including fluorosilicone. Closed Cell Expanded Chloropene Sponge (Neoprene Sponge) Grade Width (mm) Temperature Range Average Density Kg M 3 Colour Flame Resistance Medium C/+80 C 170 Black Self- Extinguishing Firm C/+80 C 180 Black Self- Extinguishing Thickness 1.5mm, 2.5mm, 3.0mm, 4.0mm, 5.0mm, 6.0mm, 8.0mm, 10.0mm Solid Neoprene Sheet Width (mm) Temperature Range Hardness Shore Colour C/+100 C 40 or 60 Black None Flame Resistance Thickness 0.5mm, 0.8mm, 1.0mm, 1.5mm, 2.0mm, 2.5mm, 3.0mm *special minimum order quantity may apply 137

138 Form-in-Place Gaskets Product Overview Kemtron Form-in-Place (FIP) Elastomer compounds are directly dispensed onto component hardware or enclosure via a pressurised fluid dispensing system on a numerically controlled XYZ table to form a gasket for RFI/EMI shielding and/or environmental seal for dust and moisture. The dispensing machine deposits the gasket by following a pre-determined CNC path to provide accuracy and repeatability. The process advantages are Component is integrated with EMI shielding and/ or environmental gasket. Materials are one-component room curable. Assembly time is reduced as gasket is included on component. Rapid prototyping. Low setup costs. Smaller gasket land required. Variety of materials available to optimise shielding and galvanic compatibility. No material waste. Excellent EMI shielding. Can be applied to metal and plastic components. 138

139 Form-in-Place Gaskets Product Overview (Continued) Applications Suited to applications where small, intricate gasket pro les are required such as on multi-compartment labyrinth housings with minimum gasket land area where traditional larger types of gasket are not suitable. This process also negates the assembly costs associated with traditional gaskets as the Form-in-Place gasket becomes an integral part of the housing or enclosure. The process is suitable for depositing on both metal and metallised plastic components/housing. Availability Kemtron can dispense FIP gaskets directly onto the customer s free issue hardware or can procure the component hardware thereby reducing the customer s supply base. Kemtron can also supply FIP compounds in syringes or Semco cartridges for the customer s own use. Form- in-place gasket materials include: For RFI/EMI Shielding Silver plated copper lled silicone. Silver plated aluminium lled silicone. Silver plated nickel lled silicone. Nickel coated graphite lled silicone. For Environmental Sealing only n lled silicone. Design Considerations o achieve optimum EMI shielding performance the component surface on which the gasket is to be deposited must be highly conductive as low contact resistance is required between the two. Chromate finishes on aluminium must be conductive. he gasket height can be speci ed between. mm to 2.0mm, gasket width will typically be 1.5x the gasket height. General tolerance is +/-0.1mm. Recommended gasket compression is between and. ver-compression can damage the gasket and as compression stops cannot be incorporated into the gasket they should be designed into the component hardware. asket path for the deposition can be determined from a sample part drawings or CA les. Production Capability o meet the varying demands of customer requirements Kemtron has developed its own CNC Form-in-Place dispenser. FIP gasketing work has become a regular feature of our production work and we are able to provide a reliable accurate and quick response to even high volume orders. Notice Information supplied in these data sheets is based on independent and laboratory tests which Kemtron believes to be reliable. Kemtron has no control over the design of customer s product which incorporates Kemtron s products, therefore it is the responsibility of the user to determine the suitability for his particular application and we recommend that the user make his own test to determine suitability. he product described in this data sheet shall be of standard quality however the products are sold without warranty of fitness for a particular purpose, either expressed or implied, except to the extent expressly stated on emtron s invoice quotation or order acknowledgement. Kemtron does not warrant that products described in this data sheet will be free of conflict with existing or future patents of third parties. All risks of lack of tness patent infringement and the like are assumed by the user. 139

140 Environmental Sealing Silicone O Rings Product Overview Kemtron s experience in the manufacture of Silicone O rings is extensive, our preferred method of production is extruded and vulcanised. We have a large selection of vulcanising tools to suit our standard extrusions. The jointing process uses the same polymer compound ensuring gasket integrity is maintained across the joints. Moulded versions are available if specifically requested. Both silicone & fluorosilicone are available for the manufacture of O rings in solid cord, tube and sponge. Please note that fluorosilicone is not available in sponge. Advantages Of Vulcanised O Rings Cost effective. No tooling costs. Reduced lead times. etter surface nish ero ash. Allows hollow sections and sponge to be used for lower compression force. Custom si es are easily produced with restriction on developed length. ight tolerances on developed length and cross section. Vulcanised rings with a I as small as mm depending on cord diameter. Design Considerations hen selecting a pro le it is important to give attention to the mechanical design of your product. Round and D section seals should ideally be mounted in a suitably si ed groove. If the gasket is to t in a groove. It is important that the gasket si e chosen does not over ll the channel when using solid sections you should ensure that the groove cross sectional area is a minimum of 5% greater than the proposed gasket cross section. Attention must also be paid to the closing force required to compress the gasket to the working height required. 140

141 Environmental Sealing Silicone O Rings Technical Specifications Tolerances Solid silicone cord and tube cross section Up to 2.0mm ± 0.15mm 2.0mm to 5.0mm ± 0.25mm 5.0mm to 9.0mm ± 0.50mm Silicone sponge cord cross section Up to 3.0mm ± 0.25mm 3.0mm to 5.0mm ± 0.50mm 6.0mm to 9.0mm ± 0.80mm Developed Length ± 1.5mm = less than ±0.5mm on diameter Cross Sections 1.00mm 1.20mm 1.30mm 1.40mm 1.50mm 1.60mm 1.80mm 2.00mm 2.20mm 2.40mm 2.50mm 2.60mm 2.80mm 3.00mm 3.20mm 3.50mm 3.80mm 4.00mm 4.30mm 4.50mm 4.80mm 5.00mm Minimum Inside Diameter of O Ring 10mm 10mm 10mm 10mm 10mm 10mm 11mm 12mm 12mm 12mm 12mm 12mm 16mm 16mm 16mm 19mm 22mm 22mm 25mm 25mm 28mm 30mm Gasket Groove Sizes 15% Compression 20% Compression Cord Diameter mm Depth Width Depth Width he above cross sectional area groove si es allow for the free movement of the gasket when being compressed. This method of calculation ensures that the volume of the gasket does not exceed that of the groove when fully compressed, resulting in groove overfill. This also minimises the amount of compression force required to achieve a good seal. It is important to note that when designing in a gasket, that the principles of O ring design for pressure sealing do not apply. The groove depth dimension is the most important, as it is this that limits the gasket compression. The groove width has no maximum dimension and is only there for gasket location purposes. Tighter groove dimensions using volume calculations may be employed to enhance environmental sealing. However this will increase the compression forces required. The above calculations are based on reducing the depth of the groove by a given compression % and increasing the width by the same amount less 5% eg. 20% reduction in depth 15% increase in width. When choosing a tube section as a gasket it is recommended that consideration be given to the lower compression forces, making sure that there is enough resilience in the gasket to ensure a good seal. In these cases it is sometimes better to use the volume groove si e calculation with the groove side walls offering support for the tube. Because there are so many variables with tube cross sections it is difficult to give precise information on this subject. Kemtron are able to supply samples for evaluation purposes. 141

142 Environmental Sealing Silicone O Rings Technical Specifications Compressed Gasket Materials Solid Silicone General Purpose Diameter Temperature Range Shore Hardness Colour Flame Resistance -60 C/+200 C 40 or 60 Grey/White None 1.5mm, 2.0mm, 2.5mm, 3.0mm, 4.0mm, 5.0mm, 6.0mm Internal Bend Radius Casting With Solid Cord Gasket Solid Flurosilicone General Purpose Diameter Temperature Range Shore Hardness Colour Flame Resistance -50 C/+200 C 40 or 60 Blue/Green None 1.5mm, 2.0mm, 2.5mm, 3.0mm, 4.0mm, 5.0mm, 6.0mm Silicone Sponge SP16 Diameter Temperature Range Density Kg/M 3 Colour Flame Resistance -55 C/+200 C 250 Grey/White None 1.5mm, 2.0mm, 2.5mm, 3.0mm, 4.0mm, 5.0mm, 6.0mm The minimum internal bend radius of a solid cord gasket is 1.5 x cross section of cord. Casting With Tube Gasket The minimum internal bend radius of a tube gasket where the id of the tube is no greater than 30% of the cross section is 2.5 x cross section of tube. 142

143 Environmental Sealing Extrusions Product Overview Kemtron s wealth of experience in profile design has enabled us to build a portfolio of extrusions suitable for a wide variety of applications. Over the years many custom sections have been successfully developed to meet demanding applications from customers world-wide. In addition our ability to fabricate, self-adhesive back and join materials broadens the applications where extruded profiles can be used. We stock many standard size sponge cords typically from 1.6mm to up to 9.5mm dia, in Silicone SP16, Neoprene & EPDM, along with similar size tube profiles in solid Silicone. In addition our in house compounding and extrusion facility enables us to run materials to customer specific requirements such as Fluorosilicone. We also have a D section range which is available in silicone sponge SP16 & SP16 V0 and hollow D solid silicones. As our stock on these products is constantly changing please contact us with your specific requirements and we will do our best to oblige. 143