Thermotech is committed to finding improved methods of meeting our customers ever changing needs and ongoing cost pressures. As part of this commitment, we have a defined process for the development of new technologies known as TIP (Thermotech Innovation Process).
One of the TIP programs that is in the final stages of development is hermetic seal insert molding. The goal of the program is to develop the necessary technology to insert mold parts that do not have a leak path along the metal to plastic interface. In conventional insert molding, no bond exists along this interface.
This inherent leak path can create failures of electronic components for various industries including: automotive, electrical, appliance, and aerospace. An example of an application for this technology would be bulkhead connectors, where the customer is trying to seal the environment on one side of the bulkhead so that neither gases nor liquids can migrate to the other side.
The current, most common solution to this leak path issue is some form of secondary operation involving potting, impregnation, molded secondary seals, or in special cases, glass bonding. Potting and impregnation are intermediate in cost. However, potting is a very messy process and impregnation usually requires outsourcing to a qualified vendor. Secondary molded seals are relatively inexpensive but do not provide true hermeticity through the bulkhead. Glass bonding techniques are very expensive.
Thermotech is in development with a solution that creates a hermetic seal through material modification. Because the most common bulkhead materials are nylon, polyesters (PBT and PET), and polyphenylene sulfide (PPS), we have chosen these resins for our initial developments. Copper and nickel were selected as our base development metals.
The amount of hermeticity required varies by application. Many applications are satisfied at leak rates less than 1X10E-5 standard cubic centimeters/ second (SCCS) of helium. We have already met this specification with both polyesters and PPS while we continue developing formulations for nylon. In fact, we have achieved leak rates less than 1X10E-9 SCCS for PPS using both copper and nickel-plated inserts.
Thermotech is continuing to evaluate samples under varying environmental and chemical conditions. We are testing samples in a variety of automotive fluids including: fuels, motor oil, transmission fluid, brake fluid, and ethylene glycol. We have also conducted various thermal cycle and thermal shock tests.
Basic principles of hermetic sealing
The process is based on several key principles:
Sealing: Creating an airtight coating around the component to prevent the penetration of external factors.
Chemical resistance: Hermetic materials must be resistant to chemicals and other aggressive substances they may come into contact with.
Mechanical resistance: The hermetic coating should withstand mechanical damage such as vibrations, impacts, or bending.
Thermal stability: Materials used must endure a wide range of temperatures without losing their properties.
Factors affecting the effectiveness of hermetic sealing
The effectiveness of hermetic sealing depends on various factors, including:
Type of hermetic material: Choosing the appropriate material (e.g., epoxy resins, polyurethanes, silicones) is crucial for ensuring effective protection.
Application technology: Methods of application such as potting, coating, or spraying can influence the quality and durability of the hermetic coating.
Surface preparation: Proper preparation of component surfaces before coating is essential. Cleaning, drying, and degreasing are necessary for achieving good adhesion of the material.
Operating conditions: The conditions in which the components will be used (e.g., humidity, temperature, pressure) must be considered when selecting materials and sealing technology.
Applications of hermetic sealing
Hermetic sealing has wide applications in various industries, including:
Electronics: Protecting integrated circuits, PCBs, sensors, and other components from moisture and dust.
LED lighting: Securing LED diodes from external factors, which increases their durability and efficiency.
Automotive: Hermetically sealing electronic components in vehicles, such as engine controllers, ABS systems, or sensors.
Aerospace and space industry: Protecting sensitive electronic components from extreme environmental conditions.
A hermetic seal is considered to have 3 types: Glass to glass seal / Glass to metal / Metal to metal seal
These seals by definition completely isolate the outside environment from what is hermetically sealed inside. These seals are meant to have zero porosity, so there is no leakage even at a molecular level.
the projects that include hermetic seals services are supported by MoldFlow Analysis, a Viscosity Curve, a Cavity Balance Study, a Pressure Window Characterization, a Gate Seal Time Study, and a Cooling Time Study. our engineers are masters of insert configuration and design single-cavity R&D molds with steel inserted areas. Interchangeable plates, inserts, and sub-inserts allow for more rapid design iterations at LOWER cost than creating new molds for each feature variation. SPI Class 103 and 104 molds are constructed from P20 steel and aluminum with hot runners and cold runners. for any question, please contact here
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