Extruded EMI Gaskets - Toptronic A/S

aerospaceclimate controlelectromechanicalfiltrationfluid & gas handlinghydraulicspneumaticsprocess controlsealing & shieldingExtruded EMI GasketsProducts & Custom Solutions CatalogChomericsENGINEERING YOUR SUCCESS.

CUSTOMER RESPONSIBILITY!WARNING – USER RESPONSIBILITYFAILURE OR IMPROPER SELECTION OR IMPROPER USE OF THE PRODUCTS DESCRIBED HEREINOR RELATED ITEMS CAN CAUSE DEATH, PERSONAL INJURY AND PROPERTY DAMAGE.• This document and other informationfrom Parker-HannifinCorporation, its subsidiaries andauthorized distributors provideproduct or system options forfurther investigation by usershaving technical expertise.• The user, through its ownanalysis and testing, is solelyresponsible for making thefinal selection of the systemand components and assuringthat all performance, endur-ance, maintenance, safety andwarning requirements of theapplication are met. The usermust analyze all aspects of theapplication, follow applicableindustry standards, and followthe information concerning theproduct in the current productcatalog and in any other materialsprovided from Parker orits subsidiaries or authorizeddistributors.• To the extent that Parker or itssubsidiaries or authorized distributorsprovide component orsystem options based upon dataor specifications provided by theuser, the user is responsible fordetermining that such data andspecifications are suitable andsufficient for all applications andreasonably foreseeable uses ofthe components or systems.OFFER OF SALEThe items described in thisdocument are hereby offered forsale by Parker Hannifin Corporation,its subsidiaries or its authorizeddistributors. This offer andits acceptance are governed by theprovisions stated in the detailed“Offer of Sale” elsewhere in thisdocument or available atwww.chomerics.com orwww.parker.com.U.S. Federal Supplier Code FSCM 18565

Extruded EMI GasketsProducts & Custom Solutions CatalogCustomer Responsibility ............................................................ 2Offer Of Sale ............................................................................... 2Chomerics Capabilities .............................................................. 4Extruded Product GuideGeneral Introduction ................................................................. 5Product Forms ........................................................................... 9Surface Preparation of Metallic Substrates ............................. 11Dimensional Guidelines ........................................................... 13Material Guidelines ................................................................. 15Guide for Standard Extruded Shapes (Profiles) ....................... 19Custom Extrusions ................................................................... 29Co-Extruded Strips .................................................................. 36MIL-DTL 83528 Part Number Cross-Reference Chart ............. 40Performance DataConductive Elastomers ............................................................ 42Application NoteCorrosion Resistance ............................................................... 47Gasket Design GuideConductive Elastomer Gasket Design Guide ............................. 51Terms of Sale ........................................................................... 69Chomerics3

Chomerics Capabilities Include:EMI SHIELDING & COMPLIANCE••••••••••••Conductive elastomers – molded, extruded, and form-in-place (FIP)Conductive foam based gaskets – fabric-over-foam and z-axis foamConductive compounds – adhesive, sealants and caulksRF and thermal/RF absorbing materialsEMI shielding plastics and injection molding servicesCoatings – direct metallization and conductive paintsMetal gaskets – Springfingers, metal mesh and combination gasketsFoil laminates and conductive tapesEMI shielding vents – commercial and military honeycomb ventsShielded optical windowsCable shielding – ferrites and heat-shrink tubing/wire mesh tape/zippered cable shieldingCompliance and safety test servicesTHERMAL MANAGEMENT & CONTROL••••••••••Thermally conductive gap filler padsDispensed thermal gap fillersSilicone-free thermal padsPhase-change materials (PCM)Polymer solder hybrids (PSH)Dispensable thermal compoundsThermal grease and gelsInsulator padsThin flexible heat spreadersCustom integrated thermal/EMI assembliesAbout Parker Hannifin CorporationParker Hannifin is the world’s leading diversified manufacturer of motion and control technologiesand systems, providing precision-engineered solutions for a wide variety of commercial, mobile,industrial and aerospace markets. For more information, visit http://www.parker.com.Chomerics 4

Heat Transfer FundamentalsExtrusion Product GuideIntroduction•••AvailabilityDesign FlexibilityCost EffectivenessProven Performance•…just four of the reasons whyconductive elastomer gaskets areso often the right EMI shieldingsolution!Once used mainly to shield criticaldefense and aerospace electronicsystems, Chomerics’ conductiveelastomer extrusions have alsobecome the progressive choice forpackaging designers of consumer,telecommunications, business andindustrial equipment, automotive,medical devices and much more.Conductive elastomers are reliableover the life of the equipment.The same gasket is both an EMIshield and an environmental seal.Elastomer gaskets resist compressionset, accommodate low closureforce, and help control airflow.They’re available in corrosion-resistantand flame-resistant grades.Their aesthetic advantages areobvious.Almost any elastomer profile can beextruded, with modest tooling costsand short lead times for eitherprototypes or large orders. Chomericscan take a customer-supplieddesign and deliver extrudedparts typically in just a few weeks.Chomerics offers hundreds of standardextrusions. Extrusions arealso readily lathe-cut into washers,spliced, bonded, kiss-cut, or evendie-cut to reduce the installationlabor and conserve material, providinga cost-effective alternative toother methods of EMI shielding andenvironmental sealing.Attachment methods range fromfriction-fit strategies to pressure-sensitiveadhesive (PSA), andinclude clip-mount options.CHO-SEAL ® & CHO-SIL ®CONDUCTIVE ELASTOMERSSince 1961, Chomerics has inventedand extended virtually every aspectof conductive elastomer materialstechnology – from the earliestsilver- and silver/copper-filledsilicones to the latest and morecost-effective silver/aluminum andnickel/graphite composites. Todaywe offer the most comprehensiveselection and highest quality productsavailable anywhere.Each conductive elastomer consistsof silicone, fluorosilicone or EPDMbinder with a filler of pure silver,silver-plated copper, silver-platednickel, silver-plated aluminum,silver-plated glass, nickel-platedgraphite or conductive graphiteparticles.The development of these compositesis the result of decades ofresearch and testing, both in thelaboratory and in the field. Ourproprietary filler powder technologyallows us to carefully control thecomposition, size and morphologyof the conductive particles. Theirprecise, uniform dispersion withinthe polymeric binders producesmaterials with stable and consistentelectrical and physical properties.Chomerics’ conductive elastomersfeature excellent resistance tocompression set over a wide temperaturerange, resulting in yearsof continuous service. In addition toEMI shielding, these materials willprovide an environmental or pressureseal, if required.Our Applications EngineeringDepartment is ready to assist withmaterial selection and gasketdesign. We welcome your inquiry!MATERIAL SELECTIONChomerics’ array of conductiveelastomers offers true flexibility inselecting the appropriate materialfor a specific application on the basisof cost and level of performancerequired. Price varies directly withshielding performance.In general, certain types of Chomerics’conductive elastomersare specified more often for military/aerospaceapplications or forcommercial applications. However,there is a considerable overlap, andour Applications Engineering Departmentwill be pleased to assistyou with product selection.For military/aerospace applications,we recommend that users of conductiveelastomer gaskets specifythat materials meet the requirementsof MIL-DTL-83528 (formerlyMIL-G-83528) and be procured fromMIL-DTL-83528 QPL sources. Toavoid the risk of system EMI or environmentalseal failure, any changein conductive elastomer seal supplier(including MIL-DTL-83528QPL suppliers) should be precededby thorough system qualificationtesting.Commercial Materials:CHO-SEAL 1273, CHO-SEAL S6305,CHO-SEAL 6370**, CHO-SEAL 6315,CHO-SEAL 6372**, CHO-SEAL 6308,CHO-SEAL L6303, CHO-SEAL 1285,CHO-SEAL 1350.Extrusion Product GuideChomerics 5

General Military/AerospaceMaterials:CHO-SEAL 1298*, CHO-SEAL 1215,CHO-SEAL 1217*, CHO-SEAL 1285,CHO-SEAL 1287*.Specialty Materials:CHO-SIL 1401, CHO-SEAL 6436,CHO-SEAL 860/862.Corrosion-Sensitive Military/Aerospace Materials:CHO-SEAL 1298*, CHO-SEAL 1285,CHO-SEAL 1287*.* Fluorosilicone; ** Flame-retardant versionSpecific material properties are listed inTable 7: Material Guidelines, pages 15-18.Table 1: General Material ApplicationsElastomers for Typical Commercial ApplicationsMaterial Filler/Binder Typical EquipmentShieldingRequirementsRemarksCHO-SEAL 1273CHO-SEAL 1285CHO-SEAL 1287CHO-SEAL S6305,6370, 6315, 6372, 6308CHO-SEAL L6303CHO-SEAL 1350Silver-plated copper insiliconeSilver-plated aluminumin siliconein fluorosiliconeNickel-clad graphite insiliconein fluorosiliconeSilver-plated glass insilicone100 dB Material of choice for high-end indoor (non-corrosive)commercial applications requiring up to 100dB of shielding,can be produced in thin-wall extrusions to decrease thecompression force required.95 – 100 dB Material of choice in high end corrosive environmentswhere corrosion and shielding of 95 -100 dB is required.Higher corrosion resistance than nickel graphite.80 – 100 dB Best material for commercial applications requiring goodperformance in moderately corrosive environments;material of choice for flange finishes due to the hardnessof the particles to penetrate through finishes to achievegood electrical contact. CHO-SEAL 6370 is UL94 V-0 rated.CHO-SEAL 6372 is 94 V-1 rated. CHO-SEAL 6315 and CHO-SEAL 6372 are cost effective alternatives to CHO-SEAL 6370and CHO-SEAL S6305. CHO-SEAL 6308 has the ability to beproduced in 0.012 inch (0.30 mm) wall thickness allowingdesigners to address mechanical design situations whichdemand small cross section gaskets.80 – 100 dB Effective material for grounding applications where DCvolume resistivity or moderate shielding is required.Elastomers for Typical Military/Aerospace ApplicationsMaterial Filler/Binder Typical EquipmentShielding RequirementsCHO-SEAL 1298CHO-SEAL 1215CHO-SEAL 1217CHO-SEAL 1285CHO-SEAL 1287Silver-plated aluminumin fluorosiliconeSilver-plated copper insiliconein fluorosiliconeSilver-plated aluminumin siliconein fluorosiliconeRemarks90 – 110 dB High performance in harshest corrosive environments; materialof choice for aircraft and marine military applications;good physical properties.105 - 120dB Resists highest level of EMP induced current; militarygasket of choice in non-corrosive environment; excellentprocessing for extrusions; 1215 preferred for thin-walledcross-sections.95 – 100 dB Military gasket of choice for corrosive environments wherethe high performance of CHO-SEAL 1298 is not requiredbut greater corrosion resistance than nickel graphite isrequired.Chomerics 6

Table 1 (cont.)CHO-SIL 1401CHO-SEAL 6436CHO-SEAL 860/862Specialty ElastomersMaterial Filler/Binder Equipment ShieldingRequirementsSilver in reticulatesiliconeSilver plated nickel inEPDMConductive graphite insiliconeRemarks80 – 100 dB High performance for non-corrosive environments;soft (45 Shore A) for low closure force where gasketshape cannot be used; low tear strength; no fluidresistance.90 dB Material of choice for high shielding where NBC fluidresistance is needed; moderate performance in corrosiveenvironments.30 – 65 dB Low-end shielding or ESD protection; no corrosionor fluid resistance. 862 is available in UL94 V-0.ADDITIONAL INFORMATION ONCHO-SEAL 1298 CORROSION-RE-SISTANT EMI SHIELDING GASKETCHO-SEAL 1298 elastomer incorporatesunique particle plating andelastomer technology for increasedcorrosion resistance. When used inconjunction with the CHO-SHIELD ®2000 series of corrosion resistantconductive coatings on aluminumflanges, a corrosion-resistant EMIflange system is obtained.CHO-SEAL 1298 gasket materialis based upon a silver-platedaluminum filler dispersed in afluorosilicone binder, with corrosioninhibiting additives that containno chromates. It offers shieldingeffectiveness of 100 dB at 500 MHzand meets all requirements of MIL-DTL-83528 Type D. CHO-SEAL 1298gasket material also has excellentresistance to fluids and fuels commonlyused in aviation and industrialapplications.CORROSION RESISTANCE TESTINGChomerics has completed extensivecorrosion resistance testingon CHO-SEAL 1298 gasket materialusing a gravimetric weightloss procedure. A copy of the testmethod (CHO-TM 100) is availableon request from Chomerics.Contact Chomerics’ ApplicationsEngineering Department for furtherinformation.LIGHTNING STRIKERESISTANCEThe survivability of any system tolightning strike is dependent onspecific flange design. Lightningstrike testing of CHO-SEAL 1298gasket material has demonstratedsurvivability beyond 5 kA/in. Testdata is available upon request.Table 2: Elastomers-Galvanic CompatibilityADDITIONAL INFORMATION ONCHO-SEAL 6370Chomerics introduced the first conductiveelastomer with a UL94 V-0rating (UL file number 96ME 17043)with allowable thicknesses downto 0.014 inch (0.356 mm). This fullyextrudable material is a corrosionresistantnickel-clad graphite filledcomposite with shielding effectivenessequivalent to or better thanother commercial grade gaskets: 95dB from 50 MHz to 10 GHz.CHO-SEAL 6372 is available with aUL 94 V-1 rating.Elastomers-Galvanic CompatibilityElastomer Filler TypeNickel Silver Silver NickelSubstrateGraphite Aluminum CopperAluminum Alloys: 6061-T6* 2 1 3 2Aluminum Alloys: 6061-T62 1 to 2 3 N/A(unplated)Chromium Plating 1 1 1 N/AGold Plating 1 1 1 N/AMagnesium 3 3 3 N/ANickel Plating** 1 2 2 1Silver Plating 1 1 1 N/AStainless Steel: 304SS, 316SS 1 1 1 N/ATin Plating 1 2 3 N/AZinc-plated Galvanized Steel 2 2 3 N/ALegend: 1 = Good 2 = Satisfactory 3 = Not RecommendedNOTE: All recommended compounds are suggested only. Customer should always test anyseal material under actual operating conditions.* Chromate conversion coating per MIL-DTL-5541F, Type I, Class 3**Nickel plating per MIL-C-26074E, Class 1, Grade B (0.0015in. thick).Chomerics 7

FLUID RESISTANCE –COMMON FLUIDSTable 3 lists the change in physicalproperties of CHO-SEAL S6305 afterexposure to a variety of commonfluids. The complete report is availablefrom Chomerics upon request.FLUID RESISTANCE –HARSH ENVIRONMENTSTable 4 lists the qualitative assessmentof fluid resistance by materialtype. The customer is encouragedto evaluate specific materials tothe requirements called for by theapplication.DUAL FUNCTIONALITYGASKETS, “CO-EXTRUSIONS”Co-extruded gaskets (dual gasketswith a conductive and non-conductiveelement cured in parallel)provide additional environmentalsealing and corrosion protection.Seam vulcanization ensures longterm integrity and stability.Co-extruded gaskets permit costeffectiveuse of existing flange designs,as well as attachment underthe less-expensive, non-conductivematerial. Compared to bondingand mounting separate gaskets,or double-groove designs, Co-extrudedgaskets offer design, costand handling advantages. See caseexample at the end of the PerformanceData section.STANDARD TOLERANCES ForCross Sectional Dimensions, inch(mm)• Less than 0.200 (5.08):± 0.005 (0.13)• 0.200 – 0.349 (5.08 – 8.86):± 0.008 (0.20)• 0.350 – 0.500 (8.89 – 12.70):± 0.010 (0.25)• Greater than 0.500 (12.70):± 3% of the nominal dimensionNOTE: Tighter tolerances areavailable upon request.Table 3: Exposure of CHO-SEAL ® S6305 to Common FluidsExposure of CHO-SEAL ® S6305 to Common FluidsNo Exposure After % ChangeExposureClearVue Tensile [psi] 200 178 -11 %Elongation [%] 289 317 +10 %Formula 409 Tensile [psi] 200 197 -2 %Elongation [%] 289 219 -24 %Windex Tensile [psi] 200 202 +1 %Elongation [%] 289 166 -43 %Carpet Cleaner Tensile [psi] 203 207 2 %Elongation [%] 414 443 7 %Coffee Tensile [psi] 203 211 4 %Elongation [%] 414 439 6 %Cola Tensile [psi] 203 199 -2 %Elongation [%] 414 433 5 %Hairspray Tensile [psi] 203 207 2 %Elongation [%] 414 326 -21 %Tire Cleaner Tensile [psi] 203 175 -14 %Elongation [%] 414 418 1 %Vinyl Protectant Tensile [psi] 203 172 -15 %Elongation [%] 414 433 4 %Tap Water Tensile [psi] 203 199 -2 %Elongation [%] 414 439 6 %Windshield Washer Tensile [psi] 203 207 2 %SolventElongation [%] 414 418 1 %Formula 409 is a trademark of the Clorox Company.Windex is a trademark of S.C. Johnson & Son, Inc.Table 4: Elastomer Fluid ResistanceElastomer Fluid ResistanceResistancesPolymer ChoiceSilicone Fluorosilicone EPDMHigh Temp Excellent Good FairLow Temp Excellent Excellent ExcellentASTM 1 Oil Fair/Good Good PoorHydraulic Fluids (Organics) Fair Good PoorHydraulic Fluids (Phosphate Ester) Poor Good PoorHydrocarbon Fuels Poor Good ExcellentHydrocarbon Fuels Poor Good ExcellentComp. Set Good Good GoodOzone, Weather Poor Poor GoodSTB (NBC Decontamination Fluid) Poor Fair/Good GoodDilute Acids Fair Good GoodNOTE: All recommended compounds are suggested only. Customer should always test anyseal material under actual operating conditions.Chomerics 8

Heat Transfer FundamentalsExtrusion Product GuideProduct FormsSTANDARD EXTRUSIONS –AN EXTENSIVE SELECTIONOur elastomer extrusions are hollowor solid strips in sizes rangingfrom 0.030 inch (0.76 mm) solid Ocross section to a 2.00 inch (51 mm)wide flat ribbon. Existing tooling,available in hundreds of sizes, allowsfor immediate production ofstandard profiles:•••••••••Solid OHollow OSolid DHollow D“Mushroom” D (patented)Solid RectangleHollow RectangleChannel StripHollow PV Strip•Standard profiles are efficient forthe majority of applications. Evenproblematic low closure force applicationscan be accommodated bylightweight, hollow gasketing.There is generally no tooling chargefor standard items. If needed, toolingof new dies for standard profilesis relatively inexpensive. Moreover,extrusions minimize material wasteand don’t require post-manufactureprocessing to remove flash. Subjectonly to packaging constraints, mostextrusions are supplied on reels.CUSTOM SHAPES IN ENDLESSVARIETYChomerics routinely produces elastomerextrusions in unusual sizesand intricate configurations to meetspecial needs. Explore the manyspecialized designs, for which toolingalready exists. This showcase,beginning on page 29 of this guide,illustrates the variety and complexitythat can be incorporated intoextruded elastomers.FINITE ELEMENTAL ANALYSIS– A POWERFUL DESIGN TOOLChomerics offers sophisticatedFEA technology to prevent falsestarts, design delays and repetitiveprototyping for unusual shieldingrequirements. Advanced computersimulation software is employed topredict gasket behavior, bypassingtrial-and-error testing. FEA notonly predicts how a design will behave,but allows it to be optimized.Complex algorithms provide criticalinformation concerning: materialselection, deformation, load-deflection,stress distribution, volume,void ratios, gland fill percent andmore. The result is a technicallysuperior solution achieved morerapidly and cost effectively thanever before.MANUFACTURING LIMITATIONSThe extruded strips listed in thisguide are generally available in allCHO-SEAL and CHO-SIL materials.However, the physical characteristicsof certain materials make themunextrudable in very small sizesand with thin wall sections. Generalmanufacturing limitations arelisted in Extrusion Profile DimensionalGuidelines, Table 6.KISS-CUT GROUNDING PADSON TAPEFor manual “peel and stick” orrobotic “pick and place” application,grounding pads are readilyproduced in quantities by kiss-cuttinghollow D (or other) extrusionsto their PSA release tape. Featuressuch as holes or slots can be incorporated,and Co-extrusions mayalso be cut. Continuous lengths aresupplied on reels.FULL-SERVICE FABRICATIONOften cost-competitive for bothsmall and large volumes, conductiveelastomer extrusionsare readily fabricated for specificapplications. These services areperformed at the factory or byChomerics’ skilled Authorized Fabricatorsthroughout the world. Visitwww.chomerics.com.Cut-To-Length (CTL). Uniform partsare supplied ready for installation.Standard Tolerances for cut parts,inch (mm)• Less than 1.00 (25.4): ± 0.020inch (0.51)• Lengths of 1.0 to 30.0 (25.4 to762): ± 0.062 (1.58)• Greater than 30.0 (762): ± 0.2%the nominal dimensionNOTE: Tighter tolerances areavailable upon request.PRECISION WASHERSSlicing solid and hollow O crosssections into disks or washers cansave time and cost, with tolerancesequivalent to molded parts. For extremelythin parts, less than 0.060inch (1.52 mm), Chomerics experienceand tooling leads the industry.Product FormsChomerics 9

SPLICED GASKETSFor fabricated gaskets with a minimuminside diameter of 2 inches(51 mm), extruded strips can bespliced to form a continuous seal.Spliced gaskets offer cost savingsover molded gaskets without sacrificingperformance. In particular,spliced hollow extrusions yieldlightweight, low closure force gasketsat considerable savings. Forsolid silicone extrusions, the spliceis often as strong and as resilient asthe gasket itself.Gaskets spliced by Chomerics orour Authorized Fabricators featurea vulcanized joint, formed underheat and pressure, that ensuresfunctionality and a more uniformjoint compared with adhesive bonding.For use with retention grooves,refer to Table 6 for recommendedinside corner radii.Spliced gaskets with an insidediameter smaller than 2 inches (51mm) are available for round, oval or“D” shaped profiles for a nominalset-up charge. Contact Chomerics’Application Engineering Departmentfor details.FRAME ASSEMBLIESChomerics fabricates completeframe/gasket assemblies either intheir entirety or using customersuppliedparts. These incorporatevulcanized joints and miters, andoften more than one gasket materialor profile. With experienceranging from handheld devices tofloor-standing equipment, size isnot a limitation.BONDED GASKETSSimilar and dissimilar compositionsand profiles can be bonded inparallel for special requirements.Capabilities include bonded-incompression stops, holes and otherfeatures.SMALL, DIE-CUT GASKETSFROM FLAT EXTRUSIONSStandard rectangular extrusionsup to 2 inches (51 mm) wide canprovide an economical means ofproducing die-cut gaskets for someapplications.PRESSURE-SENSITIVEADHESIVE (PSA)Chomerics’ extruded conductiveelastomer EMI gaskets are availablewith non-conductive pressure-sensitiveadhesive (PSA) tapefor permanent attachment. Typicalproperties for this adhesive areshown in Table 5 below. The acrylicpressure-sensitive adhesive doesnot appreciably affect the throughflangeresistance of the EMI gasket.Non-conductive PSA is preferredover conductive PSA because itexhibits higher peel strength thanconductive PSA.Table 5: PSA, Typical PropertiesAdhesive DescriptionService Temperature RangeShelf Life Conditions (from date ofmanufacture of elastomer with PSA)Application Temperature RangeInitial Peel Strength on Aluminum §Initial Peel Strength on Steel §Heat Aged Peel Strength on Aluminum †Heat Aged Peel Strength on Steel †Humidity Peel Strength on Aluminum ‡Humidity Peel Strength on Steel ‡AVAILABLE WIDTHS OF PSA,INCH (MM)• 0.050 (1.27)• 0.090 (2.29)• 0.100 (2.54)• 0.125 (3.17) min. recommended• 0.160 (4.06)• 0.200 (5.08)• 0.250 (6.35)• 0.300 (7.62)• 0.375 (9.53)• 0.500 (12.70)In general, pressure-sensitiveadhesive requires a minimum of0.125 inch (3.17 mm) flat matingsurface. For this reason, Chomericsdoes not ordinarily supply PSAon solid or hollow O strips.Pressure-Sensitive Adhesive Typical Properties§ Peel strength test data per ASTM D1000 (90° peel).† Heat aged 168 hrs. at 158°F (70°C).‡ Humidity exposure of 168 hrs. at 95% RH and 158°F (70°C).Pressure-sensitive acrylic with poly releaseliner-20 to 150°F (-29 to 66°C); PSA will functionfor short periods of time at 200°F (93°C);ultimate high temperature limit is 250°F(121°C).1 year at 70°F (21°C)/50% RH Proper storageis important!40 to 150°F (4 to 66°C)6.0 lb/inch (1.05 N/mm)6.0 lb/inch (1.05 N/mm)5.4 lb/inch (0.945 N/mm)5.4 lb/inch (0.945 N/mm)6.0 lb/inch (1.05 N/mm)6.0 lb/inch (1.05 N/mm)Chomerics 10

Extrusion Product GuideSurface Preparation of Metallic SubstratesHeat Transfer FundamentalsSURFACE PREPARATION OFMETALLIC SUBSTRATESMATERIALS REQUIRED:• 3M Scotch-Brite Pads orequivalent• Rubber gloves• Safety glasses• Lint-free cotton wipes• MEK, acetone or isopropylalcohol (IPA)Scotch-Brite is a trademark of 3M.Optimal performance of the pressure-sensitiveadhesive requiresthat the substrates to which thesegaskets must adhere are cleanedprior to application. Chomerics hasdeveloped specific, easy-to-followprocedures for preparing the followingsubstrates:••Phosphate-coated steelConversion-coated aluminumStainless and mild steel•It is essential to follow these cleaninginstructions to ensure maximumadhesion of the PSA to metalsubstrates. Failure to comply withthe appropriate cleaning processcould result in poor adhesion.Proper safety precautions should befollowed to protect the operator.SURFACE PREPARATION OFCONVERSION-COATEDALUMINUM AND PHOSPHATE-COATED STEEL1. Using a clean, lint-free applicator,moistened with MEK, acetoneor IPA, wash the surfaceuntil all traces of contaminationhave been removed.2. Clean the surface until the cottonapplicator shows no discoloration.3. If discoloration still exists,continue washing, changingthe cotton applicator eachtime, until clean. Note: Withphosphate coatings, it is veryhard to remove all discolorationfrom the surface so it is up tothe operator to determine thecleanliness of the surface priorto bonding. Typically, cleaningthe surface 3 times is required.4. Allow the substrate to dry completelyat room temperature.After the cleaning sequenceis complete, do not touch thesubstrate with bare hands.5. If the cleaned surfaces do nothave the PSA applied within an8 hour period, rewash using theabove process.SURFACE PREPARATION OFSTAINLESS OR MILD STEEL1. Using a 3M Scotch-Brite pador equivalent, lightly abrade thesteel surface.2. Blow the dust residue off ofthe steel surface with oil-freefiltered air.3. Follow Steps 1 through 5 fromthe previous section to completethe surface preparation.GASKET INSTALLATIONPROCEDURE1. Cut gasket material to specificlengths per drawing. If gasketis one piece, such as a fourcornerspliced gasket, pre-fitthe assembly to ensure fit andlocation.2. Remove a portion of the gasketliner and position the gasket.Press firmly against the gasketto tack in place. Continuepressing along the entire lengthof gasket until it is positionedand aligned to the mating surface.3. Using a rubber roller, applymoderate pressure to the entiregasket to ensure completecontact between the PSA andsubstrate surface. Note: It isimportant during the rollingprocedure that the operator notapply excessive pressure to thegasket. Extreme pressure willcause the gasket to elongateand creep as it relaxes, whichmay cause poor bonding to thesubstrate surface.Note that typically 70% of theultimate acrylic adhesive bondstrength is achieved with initialapplication, and 80-90% is reachedwithin 15 minutes. Ultimate adhesivestrength is achieved within36 hours; however the next manufacturingstep can typically occurimmediately following the initialapplication.Surface PreparationChomerics 11

OPTIMUM APPLICATIONTEMPERATURETemperatures below 50°F (10°C)can cause poor gasket adhesionto the substrate. The ideal gasketinstallation temperature is 72°F(22°C), ambient room temperature.All materials should be stored atthis temperature when not in use.Hardware and gasket materialsstored below 50°F (10°C) shouldbe brought to room temperaturebefore installing gasket.MATERIALS CONTAININGSILVERFor those materials containingsilver, both packaging and storageconditions should be similarto those for silver-containingcomponents, such as relays andswitches. They should be stored insheet plastic, such as polyester orpolyethylene, and kept away fromsulfur-containing materials, suchas sulfur-cured neoprene, cardboard,etc. To remove dirt, cleanthe elastomer with water or alcoholcontaining mild soap. Do not usearomatic or chlorinated solvents.ORDERING PROCEDUREFor standard or existing configurations,select the Chomerics partnumber from the tables that follow.The last four or five digits (representedby XXXX in the tables) designatethe material type. In additionto the parts listed, all O strips up to0.500 inch (12.7 mm) are consideredstandard. Not all combinationsof OD and ID have part numbersassigned. Contact Chomerics fordetails.For custom configurations, cut-tolengthparts, spliced parts, etc.,drawings or specifications must beprovided. Part numbers will be assignedby Chomerics upon receipt.Custom configurations requiringMIL-DTL-83528 certification or specialpackage are generally denotedby -40 or -30 suffix, respectively.Pressure-sensitive adhesive maybe ordered for any standard extrusion,other than O-strips, andmany custom profiles, which haveat least a 0.125 inch (3.17 mm)flat mating surface. The standardpart numbers listed below must bemodified to designate the PSA taperequirement. Contact Chomericsfor details.Orders must also specify quantity(feet or inches are preferred).Please note that minimum quantitiesmay apply.Our Applications EngineeringSpecialists provide shieldinggasket approaches that reduceoverall manufacturing costs.Part Numbering for Extruded ProductsExample: 10-04-1687-1215Part Number:10 = Extrusion type19 = Extrusion typeShape04 = Round05 = D-shaped06 = P-shaped07 = Rectangular08 = U-Channel09 = CustomOptional18 = Co-extrusion20 = PSA tape applied23 = Kiss cut24 = 4-Corner splicedYYYY = Cross section serialnumber (i.e., 1687)ZZZZ = Material Type(i.e., 1215)Chomerics 12

Heat Transfer FundamentalsExtrusion Product GuideDimensional GuidelinesTable 6: Dimensional GuidelinesEXTRUSION PROFILE MINIMUM DIMENSIONAL GUIDELINESMinimum dimensions suggested for manufacturing stability (all dimensions in inches)IDSWTHWTHWTWWWWSOLID D HOLLOW D HOLLOW RECT. CHANNELMin.1.5 x W 2.0 x W 2.0 x W 1.5 x WRadii: **Units: mm inch mm inch mm inch mm inchH W H W WT H W WT H W ID WT ID WT WT S WT S1215 0.889 0.889 0.035 0.035 0.413 0.290 0.290 0.017 0.114 0.114 0.508 0.635 0.020 0.025 0.508 0.508 0.020 0.0201217 0.889 0.889 0.035 0.035 0.635 3.302 3.302 0.025 0.130 0.130 0.508 0.813 0.020 0.032 0.813 0.508 0.032 0.0201273 0.889 0.889 0.035 0.035 0.432 0.290 0.290 0.017 0.114 0.114 0.508 0.635 0.020 0.025 0.508 0.508 0.020 0.0201285 1.016 1.016 0.040 0.040 0.635 3.302 3.302 0.025 0.130 0.130 0.508 0.813 0.020 0.032 0.812 0.508 0.032 0.0201287 1.016 1.016 0.040 0.040 0.635 3.302 3.302 0.025 0.130 0.130 0.508 0.813 0.020 0.032 0.812 0.508 0.032 0.0201298 1.016 1.016 0.040 0.040 0.762 3.556 3.556 0.030 0.140 0.140 0.508 0.813 0.020 0.032 0.812 0.508 0.032 0.0201350 0.889 0.889 0.035 0.035 0.635 3.302 3.302 0.025 0.130 0.130 0.508 0.813 0.020 0.032 0.812 0.508 0.032 0.0201401 1.575 1.575 0.062 0.062 1.143 4.318 4.318 0.045 0.170 0.170 0.508 1.143 0.020 0.045 1.143 0.508 0.045 0.020L6303 0.889 0.889 0.035 0.035 0.635 3.302 3.302 0.025 0.130 0.130 0.508 0.813 0.020 0.032 0.812 0.508 0.032 0.020S6305 0.889 0.889 0.035 0.035 0.635 3.302 3.302 0.025 0.130 0.130 0.508 0.635 0.020 0.025 0.635 0.508 0.025 0.0206308* 0.813 0.813 0.032 0.032 0.356 2.743 2.743 0.014 0.108 0.108 0.508 0.381 0.020 0.015 0.356 0.508 0.014 0.0206315 0.889 0.889 0.035 0.035 0.635 3.302 3.302 0.025 0.130 0.130 0.508 0.635 0.020 0.025 0.635 0.508 0.025 0.0206370 0.889 0.889 0.035 0.035 0.635 3.302 3.302 0.025 0.130 0.130 0.508 0.635 0.020 0.025 0.635 0.508 0.025 0.0206372 0.889 0.889 0.035 0.035 0.635 3.302 3.302 0.025 0.130 0.130 0.508 0.635 0.020 0.025 0.635 0.508 0.025 0.020860/862 0.889 0.889 0.035 0.035 0.508 3.048 3.048 0.020 0.120 0.120 0.508 0.635 0.020 0.025 0.508 0.508 0.020 0.020Consult Chomerics’ Applications Engineering Department concerning material compatibility for smaller dimensions and custom extrusions.* Maximum dimensional restrictions apply. Please consult with a Chomerics Application Engineer.**Typical Minimum Inside Corner RadiiLegend:ID - Inside DiameterW - WidthWT - Wall ThicknessS - Slot WidthDimensional GuidelinesChomerics 13

Table 6: Dimensional Guidelines, (Cont.)WTDIA. WT ID ODIDWTTSOLID O HOLLOW O HOLLOW P RECTANGULARMin. 1.5 x DIA. 2.0 x OD VariesRadii: *** Contact Applications EngineeringVariesContact ApplicationsEngineeringUnits: mm inch mm inch mm inch mm inchDIA. DIA. WT ID WT ID WT T ID WT T ID W T W(max)**T1215 0.762 0.030 0.432 0.508 0.017 0.020 0.508 0.762 1.143 0.020 0.030 0.045 25.4 0.787 1.000 0.0311217 0.889 0.035 0.508 0.508 0.020 0.020 0.508 0.762 1.143 0.020 0.030 0.045 25.4 0.787 1.000 0.0311273 0.762 0.030 0.432 0.508 0.017 0.020 0.508 0.762 1.143 0.020 0.030 0.045 25.4 0.787 1.000 0.0311285 1.016 0.040 0.508 0.508 0.020 0.020 0.508 0.762 1.143 0.020 0.030 0.045 25.4 0.787 1.000 0.0311287 1.016 0.040 0.508 0.508 0.020 0.020 0.508 0.762 1.143 0.020 0.030 0.045 25.4 0.787 1.000 0.0311298 1.016 0.040 0.762 0.508 0.030 0.020 0.762 0.762 1.143 0.030 0.030 0.045 25.4 0.787 1.000 0.0311350 0.889 0.035 0.508 0.508 0.020 0.020 0.508 0.762 1.143 0.020 0.030 0.045 25.4 0.787 1.000 0.0311401 1.575 0.062 1.143 0.508 0.045 0.020 1.143 1.143 1.143 0.045 0.045 0.045 25.4 1.143 1.000 0.045L6303 0.889 0.035 0.508 0.508 0.020 0.020 0.508 0.762 1.143 0.020 0.030 0.045 25.4 0.787 1.000 0.031S6305 0.762 0.030 0.635 0.508 0.025 0.020 0.635 0.762 1.143 0.025 0.030 0.045 25.4 0.787 1.000 0.0316308* 0.762 0.030 0.356 0.508 0.014 0.020 N/A N/A N/A N/A N/A N/A 12.7 0.787 0.500 0.0316315 0.762 0.030 0.635 0.508 0.025 0.020 0.635 0.762 1.143 0.025 0.030 0.045 25.4 0.787 1.000 0.0316370 0.762 0.030 0.635 0.508 0.025 0.020 0.635 0.762 1.143 0.025 0.030 0.045 25.4 0.787 1.000 0.0316372 0.762 0.030 0.635 0.508 0.025 0.020 0.635 0.762 1.143 0.025 0.030 0.045 25.4 0.787 1.000 0.031860/862 0.762 0.030 0.508 0.508 0.020 0.020 0.508 0.762 1.143 0.020 0.030 0.045 25.4 0.787 1.000 0.031Consult Chomerics’ Applications Engineering Department concerning material compatibility for smaller dimensions and custom extrusions.* Maximum dimensional restrictions apply. Please consult with a Chomerics Application Engineer.** Width of rectangular strips may exceed 1.0”, but minimum allowed thicknesses will increase.***Typical Minimum Inside Corner RadiiLegend:ID - Inside DiameterT - ThicknessW - WidthWT - Wall ThicknessChomerics 14

Extrusion Product GuideMaterial GuidelinesTable 7: Material GuidelinesPhysicalThermalElectricalRegulatoryCONDUCTIVE EXTRUDED ELASTOMER SPECIFICATIONSTest Procedure(Type of Test)CHO-SEAL1215CHO-SEAL1217CHO-SEAL1285CHO-SEAL1287CHO-SEAL1298Conductive Filler – Ag/Cu Ag/Cu Ag/Al Ag/Al Ag/AlElastomer Binder –Fluoro-Fluoro- Fluoro-SiliconeSiliconeSiliconeSilicone SiliconeType (Ref. MIL-DTL-83528) – Type A Type C Type B Type D Type DVolume Resistivity, ohm-cm,max., as supplied without pressuresensitive adhesiveCEPS-0002 (Q/C; Note C.)MIL-DTL-83528 Para. 4.5.11(Q/C)– – – – –0.004 0.010 0.008 0.012 0.012Hardness, Shore A ASTM D2240 (Q/C) 65±5 75±5 65±5 70±5 70±7Specific Gravity (± 0.025) ASTM D792 (Q/C) 3.70 3.80 1.90 2.00 2.00Tensile Strength, psi (MPa), min. ASTM D412 (Q/C) 200 (1.38) 180 (1.24) 200 (1.38) 180 (1.24) 180 (1.24)Elongation, % min. or % min./ ASTM D412 (Q/C)max.100/300 100/300 100/300 60/260 60/260Tear Strength, lb/in. (kN/m), min. ASTM D624 (Q/C) 25 (4.38) 35 (6.13) 30 (5.25) 35 (6.13) 35 (6.13)Compression Set, 70 hrs at 100°C, ASTM D395 Method B (Q)% max. (Note A.)32 35 32 30 30Low Temperature Flex TR10, °C,min.Maximum Continuous UseTemperature, °C (Note B.)Apparent Thermal Conductivity,W/m-K (Typical)Shielding Effectiveness, dB, min.(Note F.)ASTM D1329 (Q/C)(Q)ASTM D5470 (300 psi)Method 1: CHO-TM-TP08(Note C.)Method 2: MIL-DTL-83528Para. 4.5.12 (Q)-55 -55 -55 -55 -55125 125 160/200 160/200 160/2002.6 Not Tested 2.6 Not Tested 1.6Method 2 Method 2 Method 2 Method 2 Method 2200 kHz (H Field) – 70 70 60 55 55100 MHz (E Field) – 120 120 115 110 110500 MHz (E Field) – 120 120 110 100 1002 GHz (Plane Wave) – 120 115 105 95 9510 GHz (Plane Wave) – 120 110 100 90 9040 GHz (Plane Wave) CHO-TM-TP08 90 N/A N/A 75 75Electrical Stability, ohm-cm, max.Heat Aging CEPS-0002 (Q/C; Note C.) – – – – –Heat Aging MIL-DTL-83528 Para. 4.5.15(Q/C)0.010 0.015 0.010 0.015 0.015Vibration Res., During MIL-DTL-83528 Para. 4.5.13(Q)0.006 0.015 0.012 0.015 0.015Vibration Res., After MIL-DTL-83528 Para. 4.5.13(Q)0.004 0.010 0.008 0.012 0.012Post Tensile Set VolumeResistivityEMP Survivability, kA per in.perimeterMIL-DTL-83528 Para. 4.5.9(Q/C)MIL-DTL-83528 Para. 4.5.16(Q)RoHS Compliant -UL 94 Flammability Rating -0.008 0.015 0.015 0.015 0.015> 0.9 > 0.9 > 0.9 > 0.9 > 0.9Yes Yes Yes Yes YesNot Tested Not Tested Not Tested Not Tested Not TestedMaterial GuidelinesChomerics 15

Table 7: Material Guidelines (Cont.)CONDUCTIVE EXTRUDED ELASTOMER SPECIFICATIONSTest Procedure(Type of Test)CHO-SIL1401CHO-SEAL1273CHO-SEAL1350CHO-SEAL6436Conductive Filler – Ag Ag/Cu Ag/glass Ag/NiElastomer Binder – Silicone Silicone Silicone EPDMType (Ref. MIL-DTL-83528) – – – M –Volume Resistivity, ohmcm,max., as suppliedCEPS-0002 (Q/C; Note C.)0.010 0.004 – 0.050without pressure sensitiveadhesiveMIL-DTL-83528 Para. 4.5.11 (Q/C) – – 0.01 –RegulatoryElectricalThermalPhysicalHardness, Shore A ASTM D2240 (Q/C) 45 ± 5 65 ± 8 65 ± 7 80 ± 7Specific Gravity (± 0.25) ASTM D792 (Q/C) 1.60 3.70 1.80 3.80Tensile Strength, psi(MPa), min.Elongation, % min. or% min./max.Tear Strength,lb/in. (kN/m), min.Compression Set, 70 hrsat 100°C, % max. (Note A.)Low Temperature FlexTR10, °C, min.Maximum Continuous UseTemperature, °C (Note B.)Apparent ThermalConductivity, W/m-K(Typical)Shielding Effectiveness,dB, min. (Note F.)ASTM D412 (Q/C) 200(1.38)ASTM D412 (Q/C)ASTM D624 (Q/C) 20(3.50)ASTM D395 Method B (Q)ASTM D1329 (Q/C)(Q)ASTM D5470 (300 psi)Method 1: CHO-TM-TP08 (Note C.)Method 2: MIL-DTL-83528 Para.4.5.12 (Q)175(1.21)200(1.38)200(1.38)75 75 100/300 100-30(5.25)70(12.25)30 32 30 40-55 -65 -55 -45160/200 125 160 100NotTestedNotTestedNotTestedNotTestedMethod 2 Method 1 Method 2 Method 1200 kHz (H Field) – 60 - 50 -100 MHz (E Field) – 100 100 100 90500 MHz (E Field) – 100 100 100 902 GHz (Plane Wave) – 90 100 90 9010 GHz (Plane Wave) – 80 100 80 9040 GHz (Plane Wave) CHO-TM-TP08 N/A N/A 75 N/AElectrical Stability, ohm-cm, max.Heat Aging CEPS-0002 (Q/C; Note C.) – 0.01 – –Heat AgingMIL-DTL-83528 Para. 4.5.15 (Q/C)0.050.015 – 0.015(Note D.)Vibration Res., During MIL-DTL-83528 Para. 4.5.13 (Q) 0.015 - 0.009 -Vibration Res., After MIL-DTL-83528 Para. 4.5.13 (Q) 0.010 - 0.006 -Post Tensile Set MIL-DTL-83528 Para. 4.5.9 (Q/C)Volume Resistivity0.020 - 0.009 -EMP Survivability, kA MIL-DTL-83528 Para. 4.5.16 (Q)per in. perimeterRoHS Compliant -UL 94 Flammability Rating - NotTested- - - -Yes Yes Yes YesNotTestedNotTestedNotTestedChomerics 16

Table 7: Material Guidelines (Cont.)PhysicalThermalRegulatoryCONDUCTIVE EXTRUDED ELASTOMER SPECIFICATIONSTest Procedure(Type of Test)CHO-SEALS6305CHO-SEAL6315CHO-SEAL6308CHO-SEAL6370CHO-SEAL6372CHO-SEALL6303CHO-SEAL860/862Conductive Filler – Ni/C Ni/C Ni/C Ni/C Ni/C Ni/C CarbonElastomer Binder –Fluoro-Silicone Silicone Silicone Silicone SiliconeSiliconeSiliconeType (Ref. MIL-DTL-83528) – – – – – – – -Volume Resistivity, ohmcm,max., as suppliedwithout pressure sensitiveadhesiveCEPS-0002 (Q/C; Note C.) 0.10 0.75 0.10 0.10 0.75 0.10 3-24MIL-DTL-83528 Para.4.5.11 (Q/C) – – – – – – –Hardness, Shore A ASTM D2240 (Q/C) 65±10 57±7 65±10 60±10 57±7 65±10 70±5Specific Gravity (± 0.25) ASTM D792 (Q/C)1.751.28±0.032.00 1.802.10 1.80 2.302.251.20±0.03Tensile Strength,psi (MPa), min.Elongation, % min. or% min./max.Tear Strength,lb/in. (kN/m), min.Compression Set, 70 hrsat 100°C, % max. (Note A.)Low Temperature FlexTR10, °C, min.Maximum Continuous UseTemperature, °C (Note B.)Apparent ThermalConductivity, W/m-K(Typical)Shielding Effectiveness,dB, min. (Note F.)ASTM D412 (Q/C) 200(1.38)ASTM D412 (Q/C)ASTM D624 (Q/C)ASTM D395 Method B (Q)ASTM D1329 (Q/C)(Q)ASTM D5470 (300 psi)Method 1: CHO-TM-TP08(Note C.)Method 2: MIL-DTL-83528 Para. 4.5.12 (Q)140(0.96)200(138)150(1.03)150(1.03)150 (1.30)500 (3.45)600 [4.14]100 100 90 (Typ.) 100 100 60 75/10035 (6.13) 35 (6.13) 40 (7.14) 35 (6.13) 35 (6.13) 35 (6.13)50/60(8.75)30 30 30 40 30 25 --45 -40 -60 -45 -40 -45 -51150 150 150 150 150 150 1771.0 0.9NotTestedNotTestedNotTestedNotTestedNotTestedMethod 1 Method 1 Method 1 Method 1 Method 1 Method 2 Method 2200 kHz (H Field) – - - - - - - Note G.100 MHz (E Field) – 100 80 100 100 80 100 Note G.500 MHz (E Field) – 100 80 100 100 80 100 Note G.2 GHz (Plane Wave) – 100 80 100 95 80 100 Note G.10 GHz (Plane Wave) – 100 80 100 95 80 100 Note G.40 GHz (Plane Wave) CHO-TM-TP08 75 N/A N/A N/A N/A Note G.Electrical Stability, ohm-cm, max.Heat Aging CEPS-0002 (Q/C; Note C.) 0.25(Note E.)Heat AgingMIL-DTL-83528 Para.4.5.15 (Q/C)Vibration Res., During MIL-DTL-83528 Para.4.5.13 (Q)Vibration Res., After MIL-DTL-83528 Para.4.5.13 (Q)Post Tensile Set VolumeResistivityEMP Survivability, kA perin. perimeterMIL-DTL-83528 Para.4.5.9 (Q/C)MIL-DTL-83528 Para.4.5.16 (Q)RoHS Compliant -UL 94 Flammability Rating -0.85 –0.25(Note E.)0.85 0.25 -– – – – – – -0.1 - – - - 0.1 -0.1 - – - - 0.1 -- - – - - - -0.1 - – - - 0.1 -Yes Yes Yes Yes Yes Yes YesHBNotTestedNotTestedV-0 V-1NotTested860-NotTested862- V-0Chomerics 17

Table 7 NotesNote A: Compression set is expressed as a percentage of deflection per ASTM D395 Method B, at 25% deflection.To determine percent recovery, subtract 0.25 of the stated compression set value from 100%. For example, in thecase of 30% compression set, recovery is 92.5%.Note B: Where two values are shown, the first represents max. operating temp. for conformance to MIL-DTL-83528 (which requires Group A life testing at 1.25 times max. operating temp.) and the second value representsthe practical limit for exposure up to 1000 hrs. (compressed between flanges 7-10%). Single values conform toboth definitions.Note C: Copies of CEPS-0002 and CHO-TM-TP08 are available from Chomerics. Contact Applications Engineering.Note D: Heat aging condition: 100°C for 48 hrs.Note E: Heat aging condition: 150°C for 48 hrs.Note F: It may not be inferred that the same level of shielding effectiveness provided by a gasket material tested inthe fixture per MIL-DTL-83528 Para. 4.5.12 would be provided in an actual equipment flange, since many mechanicalfactors of the flange design (tolerances, stiffness, fastener location and size, etc.) could lower or enhanceshielding effectiveness. This procedure provides data applicable only to the test fixture design of MIL-DTL-83528,but which is useful for making comparisons between different gasket materials. 40 ghz test data for all materialsuses TP08 test method.Note G: Shielding Effectiveness, dB, CHO-SEAL 860, 862Compound H-Field E-Field Plane WaveCHO-SEAL 100 kHz 10 MHz 1 GHz 10 GHz860 93 77 68 88862 91 76 65 83(Q): Qualification(Q/C): Qualification & ConformanceChomerics 18

Extrusion Product GuideGuide for Standard Extruded Shapes (Profiles)Profile Description: Solid O-ShapeChomerics has or will build tooling for all outside diametersbetween 0.030 -0.500 inch (0.76 - 12.7 mm). Pleaseconsult with an Applications Engineer if the size you needis not shown in the table, and part numbers will be assigned.ØATable 8: Profiles, Solid O-Shape (Sorted by “A” Dimension)NominalDimensionSuggestedGroove Dimensions*A Depth 97% MaxPart NumberGroove Fillinch mm inch mm inch mm19-04-W993-XXXX 0.030 0.76 - - - -19-04-12897-XXXX 0.033 0.84 - - - -19-04-23913-XXXX 0.035 0.89 - - - -19-04-22085-XXXX 0.040 1.02 0.029 0.74 0.063 1.6019-04-22533-XXXX 0.043 1.09 0.032 0.81 0.064 1.6310-04-9139-XXXX 0.048 1.22 0.037 0.94 0.067 1.7019-04-22087-XXXX 0.050 1.27 0.038 0.97 0.070 1.7810-04-3560-XXXX 0.053 1.35 0.041 1.04 0.072 1.8319-04-22354-XXXX 0.060 1.52 0.047 1.19 0.078 1.9810-04-2561-XXXX 0.062 1.57 0.049 1.24 0.079 2.0119-04-22049-XXXX 0.066 1.68 0.053 1.34 0.082 2.0819-04-22951-XXXX 0.070 1.78 0.056 1.42 0.086 2.1810-04-1687-XXXX 0.070 1.78 0.056 1.42 0.086 2.1819-04-24514-XXXX 0.073 1.85 0.059 1.50 0.088 2.2419-04-12898-XXXX 0.074 1.88 0.060 1.52 0.089 2.2619-04-11228-XXXX 0.075 1.90 0.061 1.55 0.090 2.2919-04-12899-XXXX 0.077 1.96 0.063 1.60 0.091 2.3119-04-12900-XXXX 0.079 2.01 0.064 1.63 0.094 2.3910-04-2657-XXXX 0.080 2.03 0.065 1.65 0.095 2.4119-04-12901-XXXX 0.085 2.16 0.069 1.75 0.100 2.5419-04-M394-XXXX 0.090 2.29 0.074 1.88 0.103 2.6210-04-2865-XXXX 0.093 2.36 0.076 1.93 0.107 2.7210-04-3509-XXXX 0.100 2.54 0.082 2.08 0.113 2.8710-04-1720-XXXX 0.103 2.69 0.084 2.13 0.117 2.9719-04-12902-XXXX 0.106 2.62 0.087 2.21 0.119 3.0210-04-2866-XXXX 0.112 2.84 0.092 2.34 0.125 3.1719-04-22993-XXXX 0.115 2.92 0.094 2.39 0.129 3.2810-04-3077-XXXX 0.119 3.02 0.102 2.59 0.131 3.3310-04-2463-XXXX 0.125 3.17 0.107 2.71 0.139 3.5310-04-2862-XXXX 0.130 3.30 0.110 2.79 0.142 3.6119-04-12903-XXXX 0.134 3.40 0.112 2.84 0.146 3.71NominalDimensionSuggestedGroove DimensionsA Depth 97% MaxPart NumberGroove Fillinch mm inch mm inch mm19-04-23338-XXXX 0.136 3.45 0.112 2.84 0.148 3.7610-04-1721-XXXX 0.139 3.53 0.114 2.90 0.152 3.8619-04-12904-XXXX 0.147 3.73 0.120 3.05 0.160 4.0610-04-3982-XXXX 0.150 3.81 0.123 3.12 0.163 4.1419-04-12906-XXXX 0.158 4.01 0.129 3.28 0.171 4.3410-04-3231-XXXX 0.160 4.06 0.131 3.33 0.173 4.3919-04-12907-XXXX 0.170 4.32 0.139 3.53 0.182 4.6219-04-F371-XXXX 0.188 4.78 0.154 3.91 0.200 5.0819-04-12908-XXXX 0.195 4.95 0.160 4.06 0.207 5.2619-04-20919-XXXX 0.210 5.33 0.173 4.39 0.227 5.7710-04-2864-XXXX 0.216 5.49 0.177 4.50 0.234 5.9419-04-12909-XXXX 0.219 5.56 0.179 4.55 0.238 6.0419-04-12910-XXXX 0.236 5.99 0.193 4.90 0.254 6.4519-04-12911-XXXX 0.247 6.27 0.202 5.13 0.265 6.7319-04-25051-XXXX 0.275 6.99 0.226 5.74 0.291 7.3910-04-3076-XXXX 0.250 6.35 0.205 5.21 0.268 6.8110-04-9769-XXXX 0.280 7.11 0.230 5.84 0.297 7.5419-04-12912-XXXX 0.291 7.39 0.238 6.04 0.309 7.8519-04-12918-XXXX 0.367 9.32 0.301 7.64 0.387 9.8319-04-12919-XXXX 0.379 9.63 0.310 7.87 0.400 10.1619-04-12920-XXXX 0.393 9.98 0.322 8.18 0.413 10.49Standard Tolerances (inch)0.500: ±3% Nom. Dim.Dimensions listed for reference only.Please see Chomerics drawing for revision-controlled specifications.*Contact Chomerics Applications Engineering for groove designassistance.ProfilesChomerics 19

Profile Description: Hollow O ShapeChomerics has or will build tooling for all outside diametersbetween 0.030 -0.500 inch (0.76 - 12.7 mm). Please consultwith an Applications Engineer if the size you need is not shownin the table, and part numbers will be assigned.ØA ØBTable 9: Profiles, Hollow-O-Shape (Sorted by “A” Dimension)Nominal Dimension(inch)Nominal Dimension(mm)Part NumberA B A B10-04-21120-XXXX 0.053 0.020 1.35 0.5110-04-W137-XXXX 0.060 0.020 1.52 0.5110-04-W163-XXXX 0.062 0.035 1.57 0.8919-04-22710-XXXX 0.063 0.023 1.60 0.5819-04-14964-XXXX 0.070 0.020 1.78 0.5119-04-22129-XXXX 0.073 0.033 1.85 0.8419-04-24444-XXXX 0.074 0.020 1.88 0.5119-04-23365-XXXX 0.075 0.045 1.90 1.1419-04-15465-XXXX 0.080 0.030 2.03 0.7619-04-14206-XXXX 0.080 0.040 2.03 1.0219-04-11204-XXXX 0.081 0.020 2.06 0.5119-04-22678-XXXX 0.083 0.043 2.11 1.0919-04-12570-XXXX 0.083 0.050 2.11 1.2719-04-23086-XXXX 0.090 0.020 2.29 0.5110-04-W267-XXXX 0.090 0.050 2.29 1.2710-04-W293-XXXX 0.090 0.060 2.229 1.5219-04-19890-XXXX 0.093 0.033 2.36 0.8419-04-22970-XXXX 0.093 0.033 2.36 0.8419-04-20072-XXXX 0.093 0.040 2.36 1.0219-04-12744-XXXX 0.100 0.060 2.54 1.5219-04-16162-XXXX 0.100 0.070 2.54 1.7819-04-11205-XXXX 0.102 0.039 2.59 0.9919-04-20946-XXXX 0.102 0.051 2.59 1.3010-04-8363-XXXX 0.103 0.040 2.62 1.0219-04-24415-XXXX 0.103 0.053 2.62 1.3519-04-24652-XXXX 0.103 0.075 2.62 1.9019-04-11218-XXXX 0.110 0.045 2.79 1.1419-04-14120-XXXX 0.110 0.062 2.79 1.5719-04-15278-XXXX 0.110 0.068 2.79 1.7319-04-15586-XXXX 0.118 0.050 3.00 1.2719-04-12534-XXXX 0.118 0.079 3.00 2.0119-04-11216-XXXX 0.122 0.061 3.10 1.5510-04-2999-XXXX 0.125 0.045 3.17 1.1419-04-23836-XXXX 0.125 0.055 3.17 1.4010-04-8817-XXXX 0.125 0.062 3.17 1.5719-04-13564-XXXX 0.125 0.070 3.17 1.7810-04-W204-XXXX 0.125 0.078 3.17 1.98Nominal Dimension(inch)Nominal Dimension(mm)Part NumberA B A B19-04-11283-XXXX 0.125 0.080 3.17 2.0310-04-W775-XXXX 0.125 0.085 3.17 2.1619-04-23097-XXXX 0.130 0.090 3.30 2.2910-04-5514-XXXX 0.135 0.045 3.43 1.1419-04-16390-XXXX 0.135 0.045 3.43 1.1419-04-16104-XXXX 0.135 0.055 3.43 1.4019-04-16009-XXXX 0.135 0.085 3.43 2.1619-04-X787-XXXX 0.135 0.097 3.43 2.4619-04-14632-XXXX 0.137 0.087 3.48 2.2119-04-11497-XXXX 0.140 0.046 3.56 1.1719-04-11289-XXXX 0.145 0.070 3.68 1.7819-04-13118-XXXX 0.145 0.080 3.68 2.0319-04-14930-XXXX 0.151 0.094 3.84 2.3919-04-21919-XXXX 0.153 0.105 3.89 2.6719-04-13545-XXXX 0.153 0.115 3.89 2.9219-04-23209-XXXX 0.156 0.035 3.96 0.8910-04-4180-XXXX 0.156 0.050 3.96 1.2710-04-9732-XXXX 0.156 0.080 3.96 2.0310-04-8133-XXXX 0.177 0.079 4.50 2.0119-04-21639-XXXX 0.177 0.090 4.50 2.2919-04-13189-XXXX 0.177 0.110 4.50 2.7919-04-20982-XXXX 0.177 0.125 4.50 3.1719-04-22324-XXXX 0.177 0.137 4.50 3.4819-04-11214-XXXX 0.180 0.140 4.57 3.5619-04-12128-XXXX 0.188 0.125 4.78 3.1719-04-14537-XXXX 0.189 0.111 4.80 2.8210-04-4254-XXXX 0.190 0.080 4.83 2.0319-04-21194-XXXX 0.195 0.155 4.95 3.9419-04-12015-XXXX 0.207 0.077 5.26 1.9619-04-15435-XXXX 0.207 0.090 5.26 2.2919-04-16084-XXXX 0.207 0.134 5.26 3.4019-04-E483-XXXX 0.210 0.093 5.33 2.3619-04-22066-XXXX 0.210 0.100 5.33 2.5419-04-15479-XXXX 0.210 0.120 5.33 3.0519-04-C627-XXXX 0.216 0.090 5.49 2.2919-04-20848-XXXX 0.220 0.170 5.59 4.3219-04-23158-XXXX 0.236 0.118 5.99 3.00Chomerics 20

Table 9: Profiles, Hollow-O-Shape (Sorted by “A” Dimension) (Cont.)Nominal Dimension(inch)Nominal Dimension(mm)Part NumberA B A B19-04-21163-XXXX 0.250 0.110 6.35 2.7910-04-2737-XXXX 0.250 0.125 6.35 3.1719-04-15434-XXXX 0.250 0.140 6.35 3.5619-04-21162-XXXX 0.250 0.147 6.35 3.7319-04-12792-XXXX 0.250 0.150 6.35 3.8119-04-15443-XXXX 0.250 0.187 6.35 4.7519-04-21161-XXXX 0.250 0.192 6.35 4.8819-04-14349-XXXX 0.250 0.200 6.35 5.0819-04-W049-XXXX 0.290 0.156 7.37 3.9610-04-3221-XXXX 0.290 0.175 7.37 4.4419-04-19133-XXXX 0.312 0.115 7.92 2.9210-04-3004-XXXX 0.312 0.192 7.92 4.8819-04-16906-XXXX 0.335 0.202 8.51 5.1319-04-22253-XXXX 0.343 0.168 8.71 4.2719-04-13759-XXXX 0.348 0.250 8.84 6.3519-04-14292-XXXX 0.373 0.200 9.47 5.0810-04-3122-XXXX 0.375 0.250 9.52 6.3519-04-12102-XXXX 0.376 0.148 9.55 3.7619-04-22230-XXXX 0.390 0.295 9.91 7.4919-04-19324-XXXX 0.390 0.328 9.91 8.3319-04-14467-XXXX 0.394 0.253 10.01 6.4319-04-12338-XXXX 0.430 0.330 10.92 8.3819-04-3685-XXXX 0.437 0.250 11.10 6.3510-04-4034-XXXX 0.437 0.347 11.10 8.8119-04-14261-XXXX 0.461 0.295 11.71 7.4910-04-3649-XXXX 0.470 0.345 11.94 8.7619-04-11651-XXXX 0.524 0.315 13.31 8.0019-04-22208-XXXX 0.543 0.184 13.79 4.6719-04-21440-XXXX 0.545 0.395 13.84 10.0310-04-5516-XXXX 0.620 0.515 15.75 13.0819-04-15181-XXXX 0.625 0.250 15.88 6.3510-04-4148-XXXX 0.630 0.515 16.00 13.0819-04-23379-XXXX 0.644 0.581 16.36 14.7619-04-21493-XXXX 0.676 0.613 17.17 15.5719-04-11875-XXXX 0.812 0.500 20.62 12.7019-04-20951-XXXX 0.893 0.770 22.68 19.5619-04-17364-XXXX 1.240 1.150 31.50 29.21ØA ØBNOTE:Due to the hollow profile’s nature, multiple groovesizes are possible. Contact Chomerics ApplicationsEngineering for design assistance.Standard Tolerances (inch)0.500: ±3% Nom. Dim.Dimensions listed for reference only.Please see Chomerics drawing for revision-controlled specifications.Contact Chomerics Applications Engineering for groove design assistance.Chomerics 21

Profile Description: P ShapeCØA ØBDTable 10: Profiles, P-Shape (Sorted by “A” Dimension)Nominal Dimension (inch)Nominal Dimension (mm)Part NumberA B C D A B C D19-06-12489-XXXX 0.075 0.025 - 0.045 1.90 0.64 - 1.1419-06-10819-XXXX 0.076 0.028 0.124 0.033 1.93 0.71 3.15 0.8419-06-M151-XXXX 0.125 0.045 0.250 0.062 3.17 1.14 6.35 1.5719-06-Z731-XXXX 0.140 0.100 0.135 0.030 3.56 2.54 3.43 0.7619-06-C442-XXXX 0.164 0.084 0.040 0.095 4.17 2.13 1.02 2.4119-06-M412-XXXX 0.168 0.047 0.200 0.062 4.27 1.19 5.08 1.5710-06-B227-XXXX 0.190 0.130 0.312 0.062 4.83 3.30 7.92 1.5719-06-20879-XXXX 0.190 0.136 0.312 0.030 4.83 3.45 7.92 0.7610-06-A778-XXXX 0.200 0.080 0.215 0.062 5.08 2.03 5.46 1.5719-06-11223-XXXX 0.200 0.080 0.310 0.052 5.08 2.03 7.87 1.3210-06-8560-XXXX 0.200 0.080 0.425 0.062 5.08 2.03 10.80 1.5719-06-12942-XXXX 0.200 0.080 0.400 0.062 5.08 2.03 10.16 1.5710-06-8550-XXXX 0.200 0.080 0.275 0.062 5.08 2.03 6.99 1.5710-06-8737-XXXX 0.200 0.080 0.250 0.062 5.08 2.03 6.35 1.5719-06-13514-XXXX 0.200 0.080 0.125 0.062 5.08 2.03 3.17 1.5710-06-6175-XXXX 0.200 0.080 0.550 0.062 5.08 2.03 13.97 1.5710-06-3599-XXXX 0.200 0.080 0.650 0.062 5.08 2.03 16.51 1.5719-06-13217-XXXX 0.200 0.125 0.650 0.062 5.08 3.17 16.51 1.5710-06-6180-XXXX 0.250 0.125 0.625 0.062 6.35 3.17 15.88 1.5710-06-4142-XXXX 0.250 0.125 0.250 0.062 6.35 3.17 6.35 1.5710-06-3300-XXXX 0.250 0.125 0.375 0.062 6.35 3.17 9.52 1.5710-06-4921-XXXX 0.250 0.150 0.375 0.062 6.35 3.81 9.52 1.5710-06-8778-XXXX 0.250 0.250 0.350 0.062 6.35 6.35 8.89 1.5710-06-C716-XXXX 0.254 0.153 0.254 0.062 6.45 3.89 6.45 1.5719-06-22037-XXXX 0.310 0.210 0.145 0.050 7.87 5.33 3.68 1.2710-06-5611-XXXX 0.312 0.187 0.563 0.062 7.92 4.75 14.30 1.5710-06-2750-XXXX 0.360 0.255 0.420 0.070 9.14 6.48 10.67 1.7819-06-16770-XXXX 0.375 0.250 0.625 0.075 9.52 6.35 15.88 1.9019-06-L064-XXXX 0.600 0.400 0.350 0.110 15.24 10.16 8.89 2.7919-06-15899-XXXX 0.610 0.350 0.875 0.130 15.49 8.89 22.22 3.3019-06-11384-XXXX 0.750 0.625 0.725 0.062 19.05 15.88 18.41 1.57Standard Tolerances (inch)0.500: ±3% Nom. Dim.Dimensions listed for reference only.Please see Chomerics drawing for revision-controlled specifications.Contact Chomerics Applications Engineering for groove design assistance.Chomerics 22

Profile Description: Channel ShapeCDBATable 11: Profiles, Channel-Shape (Sorted by “A” Dimension)Nominal Dimension (inch)Nominal Dimension (mm)Part NumberA B C D A B C D19-08-14054-XXXX 0.075 0.099 0.025 0.032 1.90 2.51 0.64 0.8110-08-6475-XXXX 0.100 0.100 0.034 0.033 2.54 2.54 0.86 0.8419-08-22217-XXXX 0.125 0.188 0.025 0.062 3.17 4.78 0.64 1.5719-08-12880-XXXX 0.126 0.078 0.044 0.048 3.20 1.98 1.12 1.2219-08-12881-XXXX 0.126 0.099 0.047 0.059 3.20 2.51 1.19 1.5010-08-3215-XXXX 0.126 0.110 0.025 0.050 3.20 2.79 0.64 1.2710-08-4315-XXXX 0.126 0.225 0.020 0.075 3.20 5.71 0.51 1.9019-08-17623-XXXX 0.154 0.114 0.082 0.048 3.91 2.90 2.08 1.2210-08-3157-XXXX 0.156 0.156 0.062 0.047 3.96 3.96 1.57 1.1919-08-12844-XXXX 0.156 0.175 0.046 0.075 3.96 4.44 1.17 1.9010-08-3253-XXXX 0.175 0.156 0.047 0.075 4.44 3.96 1.19 1.9010-08-F815-XXXX 0.188 0.188 0.062 0.062 4.78 4.78 1.57 1.5719-08-23568-XXXX 0.190 0.270 0.050 0.065 4.83 6.86 1.27 1.6519-08-C929-XXXX 0.250 0.250 0.130 0.062 6.35 6.35 3.30 1.5719-08-12885-XXXX 0.260 0.184 0.140 0.062 6.60 4.67 3.56 1.5719-08-17068-XXXX 0.312 0.187 0.190 0.061 7.92 4.75 4.83 1.5519-08-12886-XXXX 0.320 0.315 0.193 0.197 8.13 8.00 4.90 5.0010-08-3872-XXXX 0.327 0.235 0.062 0.115 8.31 5.97 1.57 2.9210-08-8754-XXXX 0.330 0.215 0.170 - 8.38 5.46 4.32 -19-08-E622-XXXX 0.375 0.500 0.187 0.125 9.52 12.70 4.75 3.17Standard Tolerances (inch)0.500: ±3% Nom. Dim.Dimensions listed for reference only.Please see Chomerics drawing for revision-controlled specifications.Contact Chomerics Applications Engineering for groove design assistance.Chomerics 23

Profile Description: D ShapeRadius CBATable 12: Profiles, D-Shape (Sorted by “B” Dimension)Nominal Dimension (inch)Nominal Dimension (mm)Part NumberA B C A B C19-05-2116-XXXX 0.035 0.035 0.018 0.89 0.89 0.4619-05-16047-XXXX 0.021 0.040 0.010 0.53 1.02 0.2519-05-20935-XXXX 0.150 0.052 0.200 3.81 1.32 5.0819-05-23350-XXXX 0.032 0.059 - 0.81 1.50 -19-05-14769-XXXX 0.035 0.062 0.018 0.89 1.57 0.4610-05-5589-XXXX 0.055 0.064 0.031 1.40 1.63 0.7910-05-1362-XXXX 0.062 0.068 0.031 1.57 1.73 0.7919-05-14422-XXXX 0.055 0.070 0.055 1.40 1.78 1.4019-05-E163-XXXX 0.062 0.074 0.031 1.57 1.88 0.7910-05-Z337-XXXX 0.060 0.075 0.030 1.52 1.90 0.7610-05-3224-XXXX 0.094 0.078 0.047 2.39 1.98 1.1919-05-12888-XXXX 0.088 0.081 0.044 2.24 2.06 1.1219-05-12883-XXXX 0.062 0.085 0.031 1.57 2.16 0.7910-05-1363-XXXX 0.078 0.089 0.039 1.98 2.26 0.9919-05-Z586-XXXX 0.094 0.094 0.047 2.39 2.39 1.1910-05-4699-XXXX 0.062 0.100 0.031 1.57 2.54 0.7919-05-23159-XXXX 0.125 0.110 - 3.17 2.79 -10-05-2618-XXXX 0.150 0.110 0.075 3.81 2.79 1.9019-05-C128-XXXX 0.102 0.115 0.051 2.59 2.92 1.3019-05-21124-XXXX 0.165 0.118 - 4.19 3.00 -19-05-F084-XXXX 0.125 0.125 0.062 3.17 3.17 1.5710-05-A283-XXXX 0.122 0.131 0.061 3.10 3.33 1.5519-05-A611-XXXX 0.091 0.134 0.045 2.31 3.40 1.1410-05-1364-XXXX 0.122 0.135 0.061 3.10 3.43 1.5519-05-11558-XXXX 0.098 0.150 0.039 2.49 3.81 0.9910-05-1499-XXXX 0.118 0.156 0.059 3.00 3.96 1.5019-05-F173-XXXX 0.156 0.156 0.078 3.96 3.96 1.9810-05-1577-XXXX 0.178 0.175 0.089 4.52 4.44 2.2619-05-W469-XXXX 0.188 0.188 0.094 4.78 4.78 2.3910-05-A381-XXXX 0.187 0.200 0.093 4.75 5.08 2.36Standard Tolerances (inch)0.500: ±3% Nom. Dim.Dimensions listed for reference only.Please see Chomerics drawing for revision-controlled specifications.Contact Chomerics Applications Engineering for groove design assistance.Chomerics 24

Profile Description: Hollow D ShapeCTypicalBATable 13: Profiles, Hollow D-Shape (Sorted by “B” Dimension)Nominal Dimension (inch)Nominal Dimension (mm)Part NumberA B C D A B C D19-05-24810-XXXX 0.125 0.093 0.025 - 3.17 2.36 0.64 -19-05-23617-XXXX 0.085 0.095 0.020 - 2.16 2.41 0.51 -19-05-11440-XXXX 0.246 0.145 0.030 - 6.25 3.68 0.76 -19-05-9514-XXXX 0.100 0.148 0.040 - 2.54 3.76 1.02 -19-05-15343-XXXX 0.125 0.156 0.040 - 3.17 3.96 1.02 -19-05-20355-XXXX 0.135 0.156 0.040 - 3.43 3.96 1.02 -10-05-6419-XXXX 0.156 0.156 0.045 - 3.96 3.96 1.14 -19-05-21357-XXXX 0.200 0.156 0.045 - 5.08 3.96 1.14 -19-05-19354-XXXX 0.126 0.185 0.028 - 3.20 4.70 0.71 -19-05-17261-XXXX 0.186 0.186 0.040 - 4.72 4.72 1.02 -10-05-4202-XXXX 0.187 0.187 0.050 - 4.75 4.75 1.27 -19-05-11231-XXXX 0.207 0.187 0.050 - 5.26 4.75 1.27 -19-05-10277-XXXX 0.296 0.187 0.030 - 7.52 4.75 0.76 -19-05-21741-XXXX 0.296 0.187 0.030 - 7.52 4.75 0.76 -19-05-L467-XXXX 0.296 0.187 0.050 - 7.52 4.75 1.27 -19-05-17485-XXXX 0.217 0.188 0.030 - 5.51 4.78 0.76 -19-05-X254-XXXX 0.187 0.227 0.040 - 4.75 5.77 1.02 -19-05-16720-XXXX 0.400 0.230 0.035 - 10.16 5.84 0.89 -10-05-6991-XXXX 0.250 0.250 0.062 - 6.35 6.35 1.57 -10-05-6394-XXXX 0.250 0.250 0.065 - 6.35 6.35 `.65 -10-05-4308-XXXX 0.312 0.312 0.062 - 7.92 7.92 1.57 -19-05-19369-XXXX 0.312 0.312 0.038 - 7.92 7.92 0.97 -19-05-C589-XXXX 0.488 0.312 0.055 - 12.40 7.92 1.40 -19-05-16657-XXXX 0.487 0.324 0.055 - 12.37 8.23 1.40 -19-05-12375-XXXX 0.487 0.324 0.062 - 12.37 8.23 1.57 -10-05-4542-XXXX 0.487 0.324 0.080 - 12.37 8.23 2.03 -19-05-12066-XXXX 0.487 0.324 0.045 - 12.37 8.23 1.14 -19-05-20410-XXXX 0.750 0.324 0.062 - 19.05 8.23 1.57 -19-05-E429-XXXX 0.500 0.500 0.062 - 12.70 12.70 1.57 -10-05-4282-XXXX 0.700 0.600 0.100 - 17.78 15.24 2.54 -19-05-L362-XXXX 0.750 0.750 0.075 - 19.05 19.05 1.90 -Standard Tolerances (inch)0.500: ±3% Nom. Dim.Dimensions listed for reference only.Please see Chomerics drawing for revision-controlled specifications.Contact Chomerics Applications Engineering for groove design assistance.Chomerics 25

Profile Description: Rectangular Strip ShapeABTable 14: Profiles, Rectangular Strip-Shape (Sorted by “B” Dimension)Nominal Dimension (inch)Nominal Dimension (mm)Part NumberA B C D A B C D19-07-21642-XXXX 0.188 0.031 - - 4.78 0.79 - -19-07-10959-XXXX 0.870 0.032 - - 22.10 0.81 - -19-07-Z499-XXXX 0.114 0.039 - - 2.90 0.99 - -19-07-11206-XXXX 0.120 0.040 - - 3.05 1.02 - -19-07-12675-XXXX 0.500 0.040 - - 12.70 1.02 - -10-07-4272-XXXX 0.063 0.042 - - 1.60 1.07 - -19-07-11081-XXXX 1.000 0.042 - - 25.40 1.07 - -19-07-21881-XXXX 0.177 0.045 - - 4.50 1.14 - -19-07-19506-XXXX 0.320 0.045 - - 8.13 1.14 - -19-07-20218-XXXX 0.157 0.050 - - 3.99 1.27 - -19-07-20362-XXXX 0.157 0.059 - - 3.99 1.50 - -10-07-F743-XXXX 0.375 0.060 - - 9.52 1.52 - -19-07-12959-XXXX 0.640 0.060 - - 16.26 1.52 - -10-07-L525-XXXX 1.120 0.060 - - 28.45 1.52 - -19-07-12949-XXXX 0.095 0.062 - - 2.41 1.57 - -10-07-2981-XXXX 0.095 0.062 - - 2.41 1.57 - -10-07-3225-XXXX 0.125 0.062 - - 3.17 1.57 - -10-07-3047-XXXX 0.156 0.062 - - 3.96 1.57 - -19-07-F463-XXXX 0.188 0.062 - - 4.78 1.57 - -10-07-3226-XXXX 0.250 0.062 - - 6.35 1.57 - -19-07-L463-XXXX 0.390 0.062 - - 9.91 1.57 - -19-07-12200-XXXX 0.500 0.062 - - 12.70 1.57 - -19-07-12958-XXXX 0.569 0.062 - - 14.45 1.57 - -19-07-11294-XXXX 0.750 0.062 - - 19.05 1.57 - -10-07-4483-XXXX 0.750 0.062 - - 19.05 1.57 - -19-07-22989-XXXX 0.825 0.062 - - 20.95 1.57 - -10-07-4523-XXXX 0.880 0.062 - - 22.35 1.57 - -19-07-E431-XXXX 1.000 0.062 - - 25.40 1.57 - -10-07-4538-XXXX 1.180 0.062 - - 29.97 1.57 - -19-07-12961-XXXX 1.210 0.062 - - 30.73 1.57 - -19-07-16941-XXXX 1.250 0.062 - - 31.75 1.57 - -19-07-W391-XXXX 1.600 0.062 - - 40.64 1.57 - -19-07-F067-XXXX 2.000 0.062 - - 50.80 1.57 - -19-07-12954-XXXX 0.255 0.063 - - 6.48 1.60 - -19-07-12956-XXXX 0.508 0.063 - - 12.90 1.60 - -10-07-4014-XXXX 0.120 0.075 - - 3.05 1.90 - -10-07-3522-XXXX 0.500 0.075 - - 12.70 1.90 - -19-07-12948-XXXX 0.085 0.085 - - 2.16 2.16 - -Chomerics 26

ABTable 14: Profiles, Rectangular Strip-Shape (Sorted by “B” Dimension) (Cont.)Nominal Dimension (inch)Nominal Dimension (mm)Part NumberA B C D A B C D19-07-11080-XXXX 1.000 0.090 - - 25.40 2.29 - -19-07-12953-XXXX 0.188 0.093 - - 4.78 2.36 - -19-07-12491-XXXX 0.500 0.093 - - 12.70 2.36 - -19-07-11079-XXXX 0.780 0.100 - - 19.81 2.54 - -19-07-13026-XXXX 0.188 0.125 - - 4.78 3.17 - -19-07-21339-XXXX 0.250 0.125 - - 6.35 3.17 - -10-07-4217-XXXX 0.500 0.125 - - 12.70 3.17 - -19-07-12877-XXXX 0.620 0.125 - - 15.75 3.17 - -19-07-11495-XXXX 0.880 0.125 - - 22.35 3.17 - -19-07-8345-XXXX 0.980 0.125 - - 24.89 3.17 - -19-07-12951-XXXX 0.126 0.126 - - 3.20 3.20 - -19-07-12957-XXXX 0.564 0.127 - - 14.33 3.23 - -19-07-F627-XXXX 0.219 0.156 - - 5.56 3.96 - -10-07-14592-XXXX 0.438 0.188 - - 11.13 4.78 - -10-07-3080-XXXX 0.500 0.188 - - 12.70 4.78 - -10-07-B447-XXXX 0.500 0.250 - - 12.70 6.35 - -10-07-3797-XXXX 1.000 0.250 - - 25.40 6.35 - -19-07-12955-XXXX 0.330 0.305 - - 8.38 7.75 - -19-07-L956-XXXX 0.875 0.312 - - 22.22 7.92 - -19-07-16977-XXXX 1.250 0.500 - - 31.75 12.70 - -Standard Tolerances (inch)0.500: ±3% Nom. Dim.Dimensions listed for reference only.Please see Chomerics drawing for revision-controlled specifications.Contact Chomerics Applications Engineering for groove design assistance.Chomerics 27

Profile Description: Hollow Rectangle ShapeØCBATable 15: Profiles, Hollow Rectangle-Shape (Sorted by “B” Dimension)Part NumberNominal Dimension (inch)Nominal Dimension (mm)A B C A B C10-07-13944-XXXX 0.100 0.059 0.020 2.54 1.50 0.5119-07-15804-XXXX 0.126 0.126 0.048 3.20 3.20 1.2219-09-22260-XXXX* 0.500 0.280 - 12.70 7.11 -10-07-2998-XXXX 0.305 0.330 0.125 7.75 8.38 3.1710-07-4481-XXXX 0.375 0.375 0.188 9.52 9.52 4.7810-07-E263-XXXX 0.500 0.500 0.250 12.70 12.70 6.35*Profile 19-09-22260 is symmetrical hollow rectangle with 0.060 in. interior wall.Standard Tolerances (inch)0.500: ±3% Nom. Dim.Dimensions listed for reference only.Please see Chomerics drawing for revision-controlled specifications.Contact Chomerics Applications Engineering for groove design assistance.Profile Description: Mushroom D ShapeDACBTable 16: Profiles, Mushroom D-Shape (Sorted by “B” Dimension)Nominal Dimension (inch)Nominal Dimension (mm)Part NumberA B C D A B C D19-09-16802-XXXX 0.315 0.301 0.109 0.053 8.00 7.65 2.77 1.3519-09-16503-XXXX 0.265 0.312 0.113 0.040 6.73 7.92 2.87 1.0219-05-14587-XXXX 0.487 0.324 0.115 0.055 12.37 8.23 2.92 1.4019-09-14377-XXXX 0.625 0.375 0.106 0.057 15.88 9.52 2.69 1.4519-09-14926-XXXX 0.625 0.400 0.106 0.057 15.88 10.16 2.69 1.4519-05-14282-XXXX 0.645 0.427 0.065 0.065 16.38 10.85 1.65 1.6519-09-16339-XXXX 0.472 0.433 0.115 0.040 11.99 11.00 2.92 1.0219-09-15486-XXXX 0.846 0.472 0.120 0.053 21.49 11.99 3.05 1.3519-09-15523-XXXX 0.890 0.730 0.183 0.065 22.61 18.54 4.65 1.65Standard Tolerances (inch)0.500: ±3% Nom. Dim.Dimensions listed for reference only.Please see Chomerics drawing for revision-controlled specifications.Contact Chomerics Applications Engineering for groove design assistance.Chomerics 28

Extrusion Product GuideCustom ExtrusionsCustom ExtrusionCapabilitiesAs the world’s leading supplierof conductive elastomer gaskets,Chomerics routinely supports itscustomers by producing extrudedgaskets in special configurations.These range from unusual sizes instandard shapes to highly complexdesigns that meet specializedshielding and environmental sealingrequirements.The following “showcase” includesrepresentative examples of ourcustom extrusion capabilities. If youare interested in adapting one ofthese shapes to your design, ordeveloping an altogether newgasket design, contact ourApplications EngineeringDepartment. We welcome theopportunity to assist you.Custom A Profiles19-09-10076-XXXX 19-09-10645-XXXX 19-09-11540-XXXX 19-09-12057-XXXX.068.138.220.093.027.059.125.133.290.276.449.078.094.03219-09-13233-XXXX 19-09-14446-XXXX 19-09-16242-XXXX 19-09-20871-XXXX.119.225.093.068.065.094.250.252.475.187.027.122.059.187Custom Extrusions.040.125.03219-09-E053-XXXX 19-09-F948-XXXX 19-09-M942-XXXX 19-09-X962-XXXX.119.150.157.150.100.250.160.305.237.394.100.280.15719-09-24030-XXXX 19-09-24063-XXXX 19-08-24526-XXXXR.314.039.197.628.523± .008.052 2X.592 ± .010.046.046 around bulb.060Dimensions shown in inches; 1 in. = 25.4 mm.070 .105 .148.045.079R FULL R.240.100.030 TYP.340 ± .010R .010 TYP.110.060Chomerics 29

Custom D Profiles10-05-10648-XXXX 10-05-14081-XXXX19-09-14757-XXXX 19-09-19925-XXXXR.078.260.15619-09-19926-XXXX.250.149.125.045 TYP.600±.020.750±.030R.375Ø O.150±.01.139.124R .073O .052Ø O.07010-5-3369-XXXX 10-05-4318-XXXX 10-05-8635-XXXXR.081R .156R .094R .112.312 .062.312 .062Ø .083.250.125R.125.162Ø O.070R.125.312.312.17419-05-B248-XXXX 19-05-B250-XXXX 19-05-B254-XXXX 19-05-B363-XXXXR .213R .020R .156R .156Ø .181Ø O.181Ø O.248.312.371.492Ø .040.100.137.33419-09-L547-XXXX 19-09-23271-XXXX 19-09-22965-XXXX 19-09-23309-XXXX∅ .046R .030R .145∅ .14018°2XØ .040.1601.100.130.334.118.469.340.120.3151.030.114 .058.020.310.040.15019-09-23709-XXXX10-05-4035-XXXX.050 2X.062.344.594.243 2X.500.078.350.060TYP.312Custom P Profiles19-06-11400-XXXX 19-09-19944-XXXX 19-09-20733-XXXXØ .075Ø .095Ø .025Ø .360.860 ±.026Ø .045Ø .025519-09-21275-XXXX.062 ±.005112.5°R.375 ±.010.743 ±.022.094.0451.220 ±.026.070.043±.005.093±.005.0495 ±.0101.250 ±.037.062 ±.00519-09-LA06-XXXX19-09-22539-XXXXØ .200.700.062.700Ø .080.050O .100O .200Dimensions shown in inches; 1 in. = 25.4 mmChomerics 30

Custom Ribbed Profiles19-09-10921-XXXX10-09-11118-XXXX19-09-11370-XXXX19-09-11411-XXXX14X .093R. 005 TYP 14X∅ .020R .005TYP 14X14X .084∅ .088∅ .054∅ .102∅ .035∅ .025R. 005 TYP 9X∅ .05019-09-11859-XXXX19-09-13072-XXXX19-09-23139-XXXX19-09-24767-XXXX∅ .050R. 005 TYP 14X∅ .108∅ .050∅ .093R .005 TYP14X∅ .088∅ .093∅ .084R. 005 TYP 14X∅ .043∅ .098R .00514X∅ .045Custom Hat Profiles19-09-11367-XXXXØ .037R .03219-09-11408-XXXX 19-09-11409-XXXX 19-09-11641-XXXX.131.085R .032.115R .025R .016R.032.110.131.100.049.068.065.035.100.110.049.092.095.04019-09-11883-XXXX 19-09-12012-XXXX 19-09-17438-XXXX 19-09-21618-XXXXR .0182X R .010.060.075.025.0652X R .010.106.085R .032.041.100.131R.025.106R.025R.043.036.138Ø .040.098Dimensions shown in inches; 1 in. = 25.4 mmChomerics 31

Custom Mushroom Profiles19-05-14282-XXXX 19-09-14377-XXXX 19-05-14587-XXXX 19-09-14926-XXXXR .427.057 TYP.067 .427.400.645.067U.S. Patent No. 06075205 U.S. Patent No. 06075205 U.S. Patent No. 06075205.625.10619-09-15486-XXXX 19-09-15523-XXXX 19-09-16339-XXXX 19-09-16503-XXXX.040±.005.115±.005.433±.010.472U.S. Patent No. 06075205 U.S. Patent No. 06075205 ±.010U.S. Patent No. 0607520519-09-16802-XXXXU.S. Patent No. 06075205Custom Profiles19-09-10357-XXXX 19-09-10843-XXXX 19-08-10873-XXXX 19-09-11219-XXXX.500.067.266.375.240.030.200.060 .880.081.106.040.610.822.175.215.5001.000.055.10019-09-11225-XXXX 19-08-11240-XXXX 19-09-11401-XXXX 19-09-11434-XXXX.067.03365°.084.040.075 .024.024.037.096.030 ± .005.066 ± .005.019 ± .00519-09-11735-XXXX 19-09-11755-XXXX 19-09-11860-XXXX19-09-12389-XXXX.090 R .005 TYPR .01545°R .045.030.138R .005 TYP.059R .035 30°R .005 5XR .037 2X60ºR .020 4XR .125.360± 0.10.169R .025 6X.160.060R .013.025 3X R .0152X 2X.115 .175.163R .015 TYP6X3X R .050.093.017 to EDGE.11 TO INSIDE EDGE2X R .030.060 MAX4X R .020.015OF FULL R.105.180.240 4X R .015 MAX.11519-09-12756-XXXX 19-08-12876-XXXX 19-09-13225-XXXX 19-09-13569-XXXX110°.106 TYP.089Ø .375Ø .2854X .045.118.375.250.140.040.120.060.110.046 65º.8502X .375.020R .020R .010Ø .652Ø .776.250 .190.089.030.024.250140°150°.063.030R .030R .0344XDimensions shown in inches; 1 in. = 25.4 mmChomerics 32

19-09-13851-XXXX 19-09-14182-XXXX 19-09-14350-XXXX 19-09-14645-XXXXØ .188±.010Ø .118.122.480.050 TYP..050.047.040.030.300±.010.689.045 .654.082.050.309.60060°.020.47219-09-14831-XXXX 19-05-15097-XXXX 19-09-15111-XXXX 19-09-15142-XXXX.289.060R .0308X2X .070R .023.047.126R .028R .0122X .1812XR .010 2XR .02519-09-15245-XXXX 19-09-15377-XXXX 19-09-15562-XXXX 19-09-15786-XXXX.174R .117.03654°59°.081.108.379 .396 .395.035 TYP.115.085R .155.234.036.375.285.53510-09-15862-XXXX 19-09-15904-XXXX 19-08-15937-XXXX 19-09-16078-XXXX.5142X R .030R .218.040 TYPR .100R .060ø .050.40019-09-16336-XXXX 19-09-16623-XXXX 19-09-16891-XXXX 19-09-16961-XXXXR .0772X.05319-24-16966-XXXX2TRIM CLIP(ALUMINUMREINFORCEDPLASTIC TRIM).312.56.043.15658°.062 TYP.097CONDUCTIVE.31.050.312.113.265.5001.625±.049ø1.420±.043 .090 1.250±.005 ±.0381.375 ±.040.130.384.109.060Ø .075.06719-09-17276-XXXX 19-09-17428-XXXX 19-09-17429-XXXX.055R .307 ± .008.315.512 ± .015R .362 ± .010 .072R .507.335.328 ± .008.060.091.148.110.432.079.115.042Ø .035.175R .100.560R .094 2XR .064 2X.477.165.487 ± .01019-09-18963-XXXX 19-09-19022-XXXX 19-09-19234-XXXX 19-18-19561-XXXXR .479.195.3764x R .044ø .390.344.501.500.150.3761.500.025 TYP.220.777.065.280±.008.040 TYP.314R .087.373 ±.008R .015R .01024.87° typ..188.339 ±.008.501±.015Dimensions shown in inches; 1 in. = 25.4 mm.170.032 typ.Chomerics 33

19-09-19681-XXXX 19-09-19787-XXXX 19-09-19880-XXXX 19-05-20405-XXXX.198.135.443 ±.010124.8°.0393 PL.240.106.175.215.138 2X.305 ±.008.180 ±.006 2X.512 ±.020.788 ±.025.138R .030 2X19-09-20407-XXXX 19-09-20670-XXXX 19-09-21048-XXXX 19-09-21717-XXXX.079R.039 R.010.256 ±.0084X3X.150.165.059.030.148 ±.005.089.028 3X.118.312 ±.008(.070).137.551 ± .016.11819-09-A150-XXXX 19-09-A240-XXXX 10-09-A469-XXXX 19-09-C032-XXXX.640.126R .02316°.120R .022 R .062.093.115.0792X R .02019-09-C264-XXXX 19-09-C832-XXXX 19-09-E620-XXXX 19-09-F158-XXXXø.445 ø.543R .045.092.040.100.132.179.236.433.650.354.118.079.142.09119-08-F464-XXXX 19-09-F534-XXXX 19-08-F676-XXXX 19-06-L386-XXXXR .060R .020.174ø .140.190.050.190.322.040.45°.572.190.040.09019-09-L453-XXXX19-09-L524-XXXX19-09-L913-XXXX19-09-L957-XXXXø .1251.080.500ø .250R .030 TYPø .630ø .750.06030°R .015ø .260.350.061.400.060.100R .06119-09-LB05-XXXX 19-09-LD89-XXXX 19-09-LE14-XXXX 19-09-LE15-XXXXR .038.272R .03845°.450.275Dimensions shown in inches; 1 in. = 25.4 mmChomerics 34

19-09-LE24-XXXX 19-09-LF15-XXXX 19-09-LF60-XXXX 19-09-LF69-XXXX.890.040.2802X R .120.300.06019-09-LG41-XXXX 19-09-W068-XXXX 19-09-W321-XXXX 19-09-W949-XXXX.098.040.093.110 .098.033.187.050.09310-09-10824-XXXX 19-09-21467-XXXX 19-09-21862-XXXX 19-09-22079-XXXX.450.022.06545°.050.173.138.803.315.020.2582X19-09-22103-XXXX 19-09-23266-XXXX 19-09-23351-XXXX 19-09-23456-XXXX.060.100.579.079.059ø.118 2X.100.080.170.203.340.512.380.260.319.034.2772X .03419-08-23630-XXXX 19-09-23686-XXXX 19-09-24443-XXXX 19-09-24559-XXXX.138R.020R .010.071.02070.00°.335.256.070R .020.250.118.062R.0113X.083.036 TYP(.293)R.050Dimensions shown in inches; 1 in. = 25.4 mmChomerics 35

ConductiveElastomerConductiveElastomerConductiveElastomerConductiveElastomerNon-conductiveElastomerNon-conductiveElastomerNon-conductiveElastomerNon-conductiveElastomer*Note: Refer to “Surface Preparation ofMetallic Substrates” on page 11 forimportant information on proper cleaningand application. Also request TechnicalBulletin 20.Extrusion Product GuideCo-Extruded StripsCo-Extruded StripsOptimum Shielding PerformancePlus Corrosion PreventionChomerics manufactures a dualperformance extruded gasket inone simple design. By a seamvulcanization process, CHO-SEAL orCHO-SIL conductive elastomers areextruded in parallel with non-conductiveelastomers to provide EMI shieldingand corrosion protection from onegasket. The outer, non-conductivegasket acts as an extra environmentalseal to keep moisture away from theconductive gasket/flange interface.This prevents corrosion of the matingflange in marine or airborne environments.Co-extruded gaskets are alsocost-effective, as they permit the useof existing flange designs and providefor gasket attachment via a lessexpensive non-conductive elastomer.A similar two gasket shielding systemrequires a costly double groove flangedesign.Technically Superior DesignTypical examples of effective co-extrudedgaskets include commercialand military communications equipment,rack mounted cabinetry, andaircraft doors and panels. Theseapplications vary in required shieldingperformance. Each Chomericsco-extruded gasket is engineered inour applications laboratory to matchthe geometric constraints, closurerequirements and shielding performancedemanded by the application.AvailabilityMany of the gasket cross sectionshapes and sizes listed on the previouspages can also be co-extruded. Commonco-extruded configurations arepictured at left. Also refer to pages38-39 for a selection of co-extrudedshapes currently available. ContactChomerics to assist you in materialselection.Fast, Easy ConductiveElastomer Gasket Installationwith Chomerics Adhesive TapeAttachmentChomerics has developed a uniqueadhesive attachment material forCHO-SEAL or CHO-SIL conductiveEMI gaskets. This non-conductivepressure-sensitive adhesive (PSA)tape is available on most extrudedprofiles with a flat tape attachmentarea, such as D-, P-, K- and rectangularcross sections.PSA Application: This method of gasketattachment is easy and effectivewith a clean surface. Simply clean thesurface prior to mounting the gasket.*Remove the release film and positionthe gasket using light pressure. Whenthe gasket is properly positioned,firmly press onto the flange.Advantages• Peel strength (90°) in excess of4.5 pounds per inch of width (ppi)• Available in continuous length orcut to length. (Note: Some crosssections cannot be packaged incontinuous lengths.)• Eliminates fasteners or otheradhesives• Can function as a “third hand” tofacilitate difficult installations• Available with fluorosilicones as apermanent attachment method• Quick stick – readily adheres toclean surfaces• Conformable adhesion to curvedsurfaces• Resists humidity, moisture, naturalelements• Eliminates solvent emissions andlong set-up timesDisadvantages• Not available on round cross sections• Not recommended for applicationswhere solvent resistance isessential• Not recommended for applicationswhere resistance to excessiveabuse due to moving parts ortraffic is requiredChomerics 36

EMI PRODUCTS - CASE STUDIESCo-Extruded Gasket Stops Corrosion onOutdoor Telecom Enclosure.....A pole-mounted, aluminum telecom enclosure presented serious challenges for controllingEMI and keeping out the elements. The enclosure needed a conductive gasket capable of at least80 dB shielding effectiveness in the high megahertz to low gigahertz range. A separate environmentalseal was needed to protect against rain and moisture......An early gasketing approach used a non-conductive hollowsilicone strip with a pure-silver-filled silicone extrudedonto its surface. But, in contact with the aluminum housing,and exposed to coastal salt fog and driving rain, severe corrosionof the housing flanges occurred......To meet these shielding and environmental requirements,Chomerics produced a co-extruded EMI gasket. This was a CHO-SEAL ® conductive elastomer extruded in parallel with a non-conductiveelastomer. The gasket’s conductive side is a nickel-platedgraphitefilled silicone. The filler particles can bite through thinsurface oxides and chemical treatments on aluminum housings.The vulcanized seam between the elastomers provides long-termintegrity......The conductive side of this gasket was positionedinboard, with the non-conductive silicone outboard. The nonconductiveside of the cross section was designed with anadditional sealing tab to fill an existing sump area in the seamwhere rain and moisture collected......The co-extruded gasket allowed use of the existing flangedesign. It avoided the cost for separate shielding and weathersealing gaskets, and converting to a double-groove design.This is an example of how Chomerics co-extrusions offer performanceand logistical advantages at attractive prices.Table 17: Non-Conductive Extruded Elastomer Specifications*Non-Conductive Extruded Elastomer Specifications*Test Procedure(Type of Test)For more information, request ChomericsCo-extruded Elastomer Strips.CHO-SEAL2532CHO-SEAL2542CHO-SEAL2557Conductive Match - 1215/1273 1287/1298/L6303 S6305/1285/1350/1356/1285/1215/1273/6315Elastomer Binder - Silicone Fluoro-Silicone SiliconeColor - Black Light Blue Light BlueHardness, Shore A ASTM D2240 (Q/C) 60±5 70±5 65±10Specific Gravity (±0.25) ASTM D792 (Q/C) 1.5 1.68 1.55Tensile Strength, psi (MPa), min. ASTM D412 (Q/C) 400 (2.76) 500 (3.45) 200 (1.38)Elongation, % min. ASTM D412 (Q/C) 130 65 100Tear Strength, lb/in/ (kN/m), min. ASTM D624 (Q/C) 35 (6.13) 30 (5.25) 35 (6.13)*Materials used in the above chart are available to be used as Co-extrusions or bonded together with an EMI gasket.Co-Extruded StripsChomerics 37

Custom Co-Extruded Strips19-05-10168-XXXX 19-09-11771-XXXX 19-18-13715-XXXXFULL R.2XCONDUCTIVE.356.178.175NON-CONDUCTIVENON-CONDUCTIVE2X .335.197.124CONDUCTIVENON-CONDUCTIVE CONDUCTIVE.344.475.314.040 TYP19-18-F775-XXXX19-09-LD55-XXXX19-09-LE59-XXXXCONDUCTIVE.140.015.051.121.025 R, 2X.020 R, 2XNON-CONDUCTIVER .024CONDUCTIVE.050.090R .020NON-CONDUCTIVE.091.250.062 .222.150.950NON-CONDUCTIVECONDUCTIVE19-09-LH10-XXXX 19-18-LJ12-XXXX 19-18-15489-XXXX2X .090.0504X R .047CONDUCTIVE.180NON-CONDUCTIVE.1872X .0652X .031CONDUCTIVE2X .031.120.084.130.260NON-CONDUCTIVE.140.0502X .020.030NON-CONDUCTIVE.093.025.097.030CONDUCTIVE19-05-F011-XXXX 19-09-LA89-XXXX 19-09-X869-XXXX2X .089NON-CONDUCTIVE.039.078.156CONDUCTIVE.01545°NON-CONDUCTIVE2X .485.2204X R.250.1254X .062CONDUCTIVE.040NON-CONDUCTIVE.187.09.227CONDUCTIVE19-09-Z721-XXXX10-09-LH17-XXXX19-18-15351-XXXX4X R2X .250.1254X .062.188.375CONDUCTIVE2X 45°NON-CONDUCTIVE.060.270.625.114.350CONDUCTIVENON-CONDUCTIVE.120.344.517NON-CONDUCTIVE.391.501CONDUCTIVE.040TYP19-18-M391-XXXX19-18-M635-XXXX19-18-16499-XXXX.060, 2X.165.030.270.305NON-CONDUCTIVE.120.508.373.375CONDUCTIVE.354 .434CONDUCTIVE.540.030NON-CONDUCTIVE.060 TYPWALL THK.Dimensions shown in inches; 1 in. = 25.4 mmChomerics 38

19-09-LF27-XXXX 19-24-15407-XXXX Combination Gasket 19-24-12391-XXXX Combination GasketR .046 ±.005 2XCONDUCTIVE10°NON-CONDUCTIVENON-CONDUCTIVEMETALCLIP(AluminumReinforcedGasket)19-18-15351-S6305CONDUCTIVECONDUCTIVE.160NON-CONDUCTIVE.160.130± .005.260R .060 2X.563.313.115.015.06019-18-19078-XXXX 19-18-19247-XXXX 19-18-19358-XXXX(R .371)Ø .623R .031Ø .823±.015±.015CONDUCTIVENON-C O N D U C TIVE2Xø.050.150.13040° MIN3 PL40° MIN3 PL.260.060.067.110R .0102X19-18-21184-XXXXCONDUCTIVENON-COND.19-18-22999-XXXX.070CONDUCTIVENON-CONDUCTIVE19-18-23616-XXXX2X R .024.0902X R.089 ± .007Ø .650 ± .015Ø .827 ± .015.065.096.205.165NON-CONDUCTIVEConductive/Non-ConductiveMaterial Transition Zone.091±.005CONDUCTIVE19-18-24773-XXXX.235±.008R .0372X.112.075CONDUCTIVENON-CONDUCTIVEDimensions shown in inches; 1 in. = 25.4 mmCustom Co-Extruded GasketsExtruded in parallel, dual conductive/non-conductive gasketsprovide optimum EMI shielding and corrosion protectionin a single, cost-effective design. For performance and costadvantages of this approach, refer to page 36. To discuss yourrequirements, contact our Applications Engineering Department.Co-Extruded StripsChomerics 39

Extrusion Product GuideMIL-DTL-83528 Part Number Cross Reference ChartTable 18: MIL-DTL-83528 Part Number Cross Reference Chart - Sorted by MIL P/NMIL Part NumberChomerics Part NumberMIL P/N prefix* Dash #Profile Shape10-04-6386-XXXX M83528 001 Y - 001 Solid O10-04-3560-XXXX M83528 001 Y - 002 Solid O10-04-2561-XXXX M83528 001 Y - 003 Solid O10-04-1687-XXXX M83528 001 Y - 004 Solid O10-04-2657-XXXX M83528 001 Y - 005 Solid O10-04-2865-XXXX M83528 001 Y - 006 Solid O10-04-1720-XXXX M83528 001 Y - 007 Solid O10-04-3077-XXXX M83528 001 Y - 008 Solid O10-04-2463-XXXX M83528 001 Y - 009 Solid O10-04-1721-XXXX M83528 001 Y - 010 Solid O19-04-F371-XXXX M83528 001 Y - 011 Solid O10-04-2864-XXXX M83528 001 Y - 012 Solid O10-04-3076-XXXX M83528 001 Y - 013 Solid O10-05-1362-XXXX M83528 003 Y - 001 Solid D10-05-3224-XXXX M83528 003 Y - 002 Solid D10-05-1363-XXXX M83528 003 Y - 003 Solid D19-05-Z586-XXXX M83528 003 Y - 004 Solid D10-05-2618-XXXX M83528 003 Y - 006 Solid D10-05-1364-XXXX M83528 003 Y - 007 Solid D10-05-1499-XXXX M83528 003 Y - 008 Solid D19-05-F173-XXXX M83528 003 Y - 009 Solid D10-05-1577-XXXX M83528 003 Y - 010 Solid D19-05-W469-XXXX M83528 003 Y - 011 Solid D10-05-6419-XXXX M83528 007 Y - 001 Hollow D10-05-4202-XXXX M83528 007 Y - 002 Hollow D10-05-4308-XXXX M83528 007 Y - 003 Hollow D10-05-3369-XXXX M83528 007 Y - 004 Hollow D10-05-4318-XXXX M83528 007 Y - 005 Hollow D10-05-4542-XXXX M83528 007 Y - 006 Hollow D10-05-6394-XXXX M83528 007 Y - 007 Hollow D10-06-3599-XXXX M83528 008 Y - 001 Hollow P10-06-4142-XXXX M83528 008 Y - 002 Hollow P10-06-3300-XXXX M83528 008 Y - 003 Hollow P10-06-4921-XXXX M83528 008 Y - 004 Hollow P10-06-5611-XXXX M83528 008 Y - 005 Hollow P10-06-2750-XXXX M83528 008 Y - 006 Hollow P10-06-8550-XXXX M83528 008 Y - 007 Hollow P10-06-6180-XXXX M83528 008 Y - 008 Hollow PChomerics 40

Table 18: MIL-DTL-83528 Part Number Cross Reference Chart (Cont.)Chomerics Part NumberMIL Part NumberMIL P/N prefix* Dash #Profile Shape10-07-4272-XXXX M83528 009 Y - 001 Rectangular10-07-2981-XXXX M83528 009 Y - 002 Rectangular10-07-4014-XXXX M83528 009 Y - 003 Rectangular10-07-3225-XXXX M83528 009 Y - 004 Rectangular10-07-3047-XXXX M83528 009 Y - 005 Rectangular10-07-3226-XXXX M83528 009 Y - 006 Rectangular10-07-3522-XXXX M83528 009 Y - 007 Rectangular10-07-4217-XXXX M83528 009 Y - 008 Rectangular10-07-3080-XXXX M83528 009 Y - 009 Rectangular10-07-4483-XXXX M83528 009 Y - 010 Rectangular10-07-4523-XXXX M83528 009 Y - 011 Rectangular10-07-3797-XXXX M83528 009 Y - 012 Rectangular10-07-4538-XXXX M83528 009 Y - 013 Rectangular10-08-6475-XXXX M83528 010 Y - 001 Channel10-08-3215-XXXX M83528 010 Y - 002 Channel10-08-4315-XXXX M83528 010 Y - 003 Channel10-08-3157-XXXX M83528 010 Y - 004 Channel10-08-3253-XXXX M83528 010 Y - 005 Channel10-08-3872-XXXX M83528 010 Y - 006 Channel10-04-2999-XXXX M83528 011 Y - 001 Hollow O10-04-4180-XXXX M83528 011 Y - 002 Hollow O10-04-2737-XXXX M83528 011 Y - 003 Hollow O10-04-3004-XXXX M83528 011 Y - 004 Hollow O10-04-3122-XXXX M83528 011 Y - 005 Hollow O10-04-8817-XXXX M83528 011 Y - 006 Hollow O10-04-8363-XXXX M83528 011 Y - 007 Hollow O10-04-8133-XXXX M83528 011 Y - 008 Hollow OMIL-DTL Cross Reference* MIL part number is MIL P/N prefix with Dash # as suffix. “Y” should bereplaced by applicable MIL-DTL-83528 material type (e.g., A, B, C, etc.).Chomerics 41

Performance DataConductive ElastomersCompression-DeflectionWhile standard test procedures havebeen established for measuringthe deflection of elastomers undercompressive loads, the practicaluse of such data is to provide aqualitative comparison of the deformabilityof different elastomericmaterials when in the particularconfiguration of the test sample.Solid (non-foam) elastomers areessentially incompressible materials;i.e., they cannot be squeezedinto a smaller volume. When a solidelas tomer is subject to a compressiveload, it yields by deformation ofthe part as a whole. Because of thisbehavior, the actual deflection of agasket under a compressive loaddepends upon the size and shape ofthe gasket as well as on its modulusand the magnitude of the load.The design of a seal should be suchthat it will be subjected to the minimumsqueezing force sufficient toprovide the required mechanicaland electrical performance. Thedesigned deflection of conductiveelastomer gaskets should never exceedthe maximum deflection limitsshown in Table 19.Table 19: Recommended DeflectionsRecommended Deflection for VariousConductive Elastomer ShapesCrossSectionGeometeryMin.DeflectionNominalDeflectionSolid O 10% 18% 25%Solid D 8% 15% 20%Rectangular(includingdie-cut)5% 10% 15%Hollow O, Dand P10%-15%*50% ofinsideopeningMax.Deflection100% ofinsideopeningNOTE: For increased deflectionrequirements, Chomerics can providespecific shapes.*15% on thin wall

There is an approximate relationshipbetween the force required todeflect a pure elastomer a givenamount, and the hardness of theelastomer. In general, the harderthe elastomer, the greater the forcerequired. In the case of Chomerics’metal particle-filled elastomers,this relationship is much less definite,and in some instances, thesematerials demonstrate deflection/hardness and deflection/thicknessbehavior contrary to that whichwould be anticipated for conventionalelastomer compounds.The inclusion of metal particlesin the elastomer results in a mechanicallystructured material. Thismechanical structure has a markedeffect on the deflection of the elastomerunder compressive loads,and in some instances, hardermaterials deflect more than softermaterials.Compressive load-deflection datafor many popular conductive elastomermaterials and shapes are givenin Figures 1-6. (For “line contact”gaskets, it is more convenient toexpress the load in terms of poundsper linear inch instead of poundsper square inch).For compression-deflection data onother Chomerics gaskets, contactour Applications EngineeringDepartment.Load (lbs / linear inch)Figure 4. Hollow D H 0.156” Wall Thickness 0.45”Load (psi)Figure 5. Sheet Stock 0.032”Load (psi)Deflection vs. Load - 19-05-6419 @ 0.025 in/min.Tested with 1” x 1” Cu probe1298Deflection (%) of Height128513106370121512851350Deflection vs. Load - 40-20-0505 (~30 mil) @ 0.025 in/min.Tested with 1” x 1” Cu probeRecommended Max.Deflection (%)Deflection vs. Load - 40-30-0505 (~60 mil) @ 0.025 in/min.Tested with 1” x 1” Cu probe129863701310128512151298S6305Performance DataRecommended Max.Deflection (%)Figure 6. Sheet Stock 0.062”Chomerics 43

sured at 700 MHz. Die-cut gaskets0.144 in. wide by 0.062 in. thick, ina wide range of resistivities, wereclamped between the gold-platedflanges of this enclosure. Simultaneousmeasure ments of flangeinterface resistance (all attributableto the gaskets) versus RF leakagethrough the seam produced a classicS-shaped curve. For the gasketconfiguration used in this test, thedramatic change in shielding effectivenessoccurs between gasketvolume resistivities of 0.01 and 0.4ohm-cm. Since real enclosures donot have gold-plated flanges, butrather have surface finishes (suchas MIL-DTL-5541F, Type I, Class3 chromate conversion coatings)which also increase in resistanceover time, it is recommended thatgasket volume resistivity be specifiedat 0.01 ohm-cm max. for thelife of the equipment.Interface Resistance, milliohms100.010.01.00.10.01Tested at 700 MHzEnclosure: 3" X 3" X 4" Deepwith Gold-Plated FlangesEnclosure Material: .500" Aluminum0 10 20 30 40 50 60Shielding Degradation, dBGasket Resisance (m/in.)1.751.501.251.000.750.500.25Material #1(1350)Material #2(1224)Material #4(1215)Material #3(1285)0 0.5 1.0 1.5 2.0 2.5Peak Pulse Current (kA/in.)Figure 12. EMP Current Response of ConductiveElastomer Gaskets(1350) become nonconductive at lowlevels of EMP current, and shouldtherefore not be used when EMP isa design consi d eration. Figure 13 isan electron microscope photo whichclearly shows the damage mechanism.Silver-plated-copper filled(1215) gaskets have the highestresistance to EMP type currents,showing no loss of conductivity evenat 2.5 kA/inch of gasket (peakto-peak).Pure silver (1224) andsilver-plated-aluminum filled (1285)gaskets have less current carryingcapability than silver-plated-coppermaterials, but are generally acceptablefor EMP hardened systems(depending on specific EMP threatlevels, gasket cross section dimensions,etc.).Vibration ResistanceCertain conductive elastomers areelectrically stable during aircraftlevelvibration environments, whileothers are not. The key factor whichdeter mines vibration resistance isthe shape and surface texture of thefiller particles. Smooth, sphericalfillers (such as those used in silverplated-glassmaterials) tend tomove apart during vibration, leadingto dramatic increases in resistanceand loss of shielding effectiveness(although they normally recovertheir initial properties after thevibration has ended). Rough, lessspherical particles resist vibrationwith very little electrical degradation.Figure 14 shows the effects ofvibra tion on three types of conductivegaskets. Although ChomericsLeakage (dB)605040302010Ag/Glass Filler0 0 1 2 3 4 5 6Vibration (g)Spherical Ag/Cu FillerChomerics Ag/Cu FillerFigure 14. Effects of Vibration on ShieldingEffectiveness of ConductiveElastomer Gasketssilver-plated-copper filled 1215gasket, with rough, irregular particleagglomera tions, exhibits excellentstability during vibration, users ofconductive elastomers should beaware that smooth, spherical silverplated-copperfillers can be almostas unstable as silver-plated-glassfillers.Performance DataFigure 11. Interface Resistance vs. ShieldingDegradation at a Flange JointEMP SurvivabilityIn order for an enclosure to continueproviding EMI isolation duringand after an EMP environment, theconductive gaskets at joints andseams must be capable of carryingEMP-induced current pulses withoutlosing their conductivity. Figure12 shows the EMP current responseof various types of conductive elastomergaskets. Note that gasketsbased on silver-plated-glass fillersFigure 13. Scanning Electron Microscopy Illustrates EMP DamageMechanism for Silver/Glass ElastomersChomerics 45

Heat AgingThe primary aging mechanismwhich affects electrical stability ofconductive elastomers is the oxidationof filler particles. For materialsbased on pure silver fillers,particle oxidation is not generally aproblem because the oxide of silveris relatively soft and reasonablyconductive. If the filler particles arenon-noble (such as copper, nickel,aluminum, etc.) they will oxidizereadily over time and becomenonconductive. Even silver-platedbase metal powders, such as silverplated-copperor silver-plated-aluminumwill become non-conductiveover time if the plating is not doneproperly (or if other processing variablesare not properly controlled).These are generally batch controlproblems, with each batch beingpotentially good or bad.The most reliable method ofpredicting whether a batch will beelectrically stable is to promotethe rate at which poorly plated orprocessed particles will oxidize,by heat aging in an air circulatingoven. For qualifica tion, 1000Volume Resistivity (ohm-cm).010.001Hours at 125C (Dotted Line)0 500 100048 Hours1000 HoursAged at 150 in Unflanged Condition(See bottom axis)Aged at 125 in Flanged Condition(See top axis)0 8 16 24 32 40 48Hours at 150C (Solid Line)Figure 15. Typical heat aging characteristicsof Chomerics plated-powder-filledconductive elastomers. Flanged1000-hr test recommendedfor qualification. Unflanged 48-hr.test recommended for QC acceptance.hours (42 days) at maximum rateduse temperature (with the gasketsample deflected 7-10% betweenflanges) is the recom mended heataging test for accelerating the effectsof long-term aging at normalambient tempera tures. A quickerheat aging test, which correlateswell with the 1000 hour test and isuseful for QC acceptance testing,involves a 48 hour/150°C oven bakewith the gasket sample on an openwire-grid tray (rather than beingclamped between flanges). Figure15 shows typical data for volumeresis tivity versus time for each ofthese tests.Note: It is essential that no sourceof free sulfur be placed in the agingoven, as it will cause the material todegrade electrically and mask anyoxidation aging tendencies. Commonsources of sulfur are neoprenes,most cardboards and otherpaper products.Table 20: Outgassing Data for Conductive ElastomersOutgassing Data for Conductive Elastomers(Per ASTM E595-93)SpecialPost CuringOutgassingMany spacecraft specifications requirethat nonmetallic componentsbe virtually free of volatile residueswhich might outgas in the hardvacuum environment of space. Thestandard test method for determiningoutgassing behavior is ASTME595-93, which provides for measurementof total mass loss (TML)and collected volatile condensablematerials (CVCM) in a vacuumenvironment. Data for a number ofChomerics conductive elastomers,based on ASTM E595-93 testingdone by NASA Goddard SpaceflightCenter, is presented in Table 20.The normal specification limits orguide-lines on outgassing for NASAapplications are 1% TML max.,and 0.1% CVCM max.TML %Limit

Application NoteCHO-SEAL ® 1298 Corrosion Resistant EMI Shielding GasketKEY FEATURES• New particle technology offersincreased corrosion resistancewith no chromates• 90 dB shielding effectiveness– 100 MHz-10 GHz• Meets all requirements of MIL-G-83528 Type D (initial and aged)• Excellent resistance to jet fuelsand fluids used in aviation andindustrial applications.PRODUCT DESCRIPTIONThrough the use of new proprietaryparticle plating and elastomer compoundingtechnology, CHO-SEAL ®1298 shielding elastomer offersapproximately a 200% increase incorrosion resistance over productspreviously available. In fact,a virtually corrosion-proof EMIflange system is obtained whenCHO-SEAL ® 1298 gaskets are usedin conjunction with Chomerics’CHO-SHIELD ® 2000 series corrosion-resistantcoatings on aluminumflanges. Using a combinationof fabric reinforcement and wiremesh for superior lightning currenthandling abilities, CHO-SEAL®1298 elastomer is highly recommendedfor HIRF/lightning seals forcommercial and military aircraft.Unlike nickel-filled and carbonfilledelastomers, CHO-SEAL ® 1298is electrically stable even afteraccelerated heat aging. In everyrespect, CHO-SEAL ® 1298 outperformsnickel, nickel-graphite andcarbon-filled EMI gasket materialsin aluminum joints. See Table 1 forproduct specifications.CHO-SEAL ® 1298 material has afluorosilicone binder, with corrosioninhibiting additives which containno chromates. This allows for safehandling and easy material storagewithout the use of protective clothingor restricted areas.The proprietary additives do notdegrade the physical performanceComparison of corrosion results obtained from CHO-SEAL® 1298 conductive elastomer(left) and pure silver-filled elastomer (right) mated with aluminum after 168 hours of salt fogexposure.expected of fluorosilicone materials.CHO-SEAL ® 1298 material hasexcellent resistance to fluids andfuels commonly used in aviationand industrial applications.CORROSION RESISTANCEUsing a weight loss procedure, thecorrosivity of CHO-SEAL ® 1298material and other EMI gasketswas measured. Table 2 shows theweight loss 6061-T6 aluminum incontact with different EMI gasketmaterials after 168 hours of ASTMB117 salt fog exposure. The couponis conversion-coated per MIL-DTL-5541F, Type I, Class 3.These results show that using thegalvanic series to predict corrosivityof conductive elastomers can be incorrectand misleading. Conductiveelastomers are composite materialsand the metal core plays a rolein determining corrosion properties.CHO-TM100 is a test method todetermine, in a quantitative manner,the corrosivity of conductiveelastomers toward aluminum alloysand the electrical and dimensionalstability of the conductive elastomerafter exposure to salt fog environment.This is a non-subjective testresulting in repeatable, measurablehard data and not subjectiveratings.The test fixture is shown in Figure 1.The conductive elastomer and aluminumcoupon are held in contactby compression between two cylindricalDelrin ® blocks. Compressiveforce is supplied by a central 3.25”(8.26cm) long ¼-20, 18-8 stainlesssteel bolt and an 18-8 stainlesssteel nut. Fluid is prevented frompenetrating to the bolt conductiveelastomer/aluminum alloy couponinterface by use of non-conductivesilicone sealing washers betweenApplication NoteChomerics 47

1/4-20 Cres FastenerTable 1: SpecificationsNon-ConductiveSealing GasketNon-ConductiveSealing GasketUpper Delrin BlockConductive GasketAluminumAlloy CouponLowerDelrin BLockFigure 1: Test Fixturethe bolt head and the upper Delrinblock and between the bottom ofthe aluminum coupon and the lowerDelrin block.Test results are based on 168 hoursexposure to chromate treated aluminumper MIL-DTL-5541F, TypeI, Class 3. The fixture is exposedto neutral salt fog according to theconditions given in ASTM B117.This test procedure can be usedwith SO 2salt fog and/or other substratesin place of aluminum.CHO-TM100 test procedure hasbeen adopted by major aerospace,military and aircraft manufacturers.A copy of the test is available on requestfrom Chomerics. Chomericswill supply test fixtures and elastomersamples for testing under yourcontrol.Table 3 compares the electrical stabilityof several conductive elastomersafter 192 hours of SO 2salt fogexposure (ASTM G85, Annex A4).CORROSION PROOF FLANGEDESIGN WITH CHO-SHIELD2000 SERIES COATINGSCHO-SEAL ® 1298 gaskets and CHO-SHIELD ® 2000 series of conductiveflange coatings form a virtuallycorrosion proof EMI sealing system.Superior corrosion proof sealingresults have been obtained followingboth CHO-TM 200 and 201 TestProcedures. CHO-TM200 is a testmethod for performing shielding ef-1.25’Dia.1.50’ Dia.1.75’ Dia.1.00’1.00’Property Test Method CHO-SEAL 1298Elastomer Binder - FluorosiliconeConductive Filler - Passivated Ag/AlVolume Resistivity, as supplied MIL-G-83528 Para. 4.6.11 0.012ohm-cm, max.Gravimetric Weight Loss, mg CHO-TM100 0.91 After 168 hours exposure to neutral salt fog per ASTM B117 with chromate treated aluminum per MIL-DTL 5541F, Type I, Class 32 After 168 Hours exposure to neutral salt fog per CHO-TM100 and ASTM B117 against chromate treated aluminum per MIL-DTL 5541F, Type I, Class 3Table 2: Typical Weight Loss of 6061-T6 Aluminum Coupons*Material Type Typical Weight Loss (mg) Volume Resistivity(ohm-cm)CHO SEAL 1298

Table 3: Typical Volume Resistivity Before and After SO 2Salt FogVolume Resistivity (ohm-cm)Material Type Before AfterCHO-SEAL 1298 0.008 0.014Standard Ag/Al, MIL-G-83528,Type D*0.005 0.020Ni-filled Silicone 0.011 3.57Ni/Graphite-filled silicone 0.081 0.253*Values represent averages based on samples from various vendors.fectiveness measurements on EMIgasketed flange systems before andafter environmental exposure.CHO-TM201 is intended to allowevaluation of shielding effectivenessof different flange treatments,gasket materials and configurationsafter each cycle of environmentalexposure. Both procedures areavailable on request fromChomerics.Test “Set”The shielding effectiveness ofCHO-SEAL ® 1298 gasket againstClass 3 chromate conversion coatedaluminum protected with CHO-SHIELD 2001 or 2002 coatings ishigher even after 1000 hours ofASTM B117 salt fog than the samegasket against conversion coatedflanges with no salt fog exposure.See Figure 2.Figure 2: CHO-SEAL ® 1298 Gasket Against Aluminum (CHO-SHIELD 2001 Coating) Beforeand After 500 and 1000 Hours of Salt Fog ExposureEMI GasketAdapter Test PlateShielded Enclosure WallChomerics test report CHO-TR19Edescribes how the effects of salt fogexposure on the shielding effectivenessof CHO-SEAL ® 1298 gasketsagainst various aluminum flangetreatments were determined. Thiswas configured as defined withinChomerics’ shielding effectivenesstest method CHO-TM201. Figure 3illustrates the test plate set assembly.A copy of CHO-TH19 is availableon request from Chomerics.Figure 4 illustrates the retention ofvolume resistivity and lack of weightloss in CHO-SEAL ® 1298 gasketsafter 1,000 hours of neutral salt fog.CHO-SHIELD 2001, 2002, and 2003electrically conductive coatingsprovide corrosion protection forenclosure flanges which mate withEMI shielding gaskets. They canalso provide a corrosion resistantconductive surface coating on aluminumor plastic substrates.CHO-SHIELD 2000 series coatingsare three-part, copper-filled urethaneswith filler systems treated toremain electrically stable at elevatedtemperatures. A number ofstabilizers prevent the copper fromcorroding in high humidity and/ormarine environments.CHO-SHIELD 2001 and 2003 containsoluble chromates to minimize theeffects of galvanic corrosion of thealuminum substrate, even in theevent of a coating scratch. TheCHO-SHIELD 2002 coating, primarilyintended for composite substratesor as 2001 repair coating, ischromate-free. They can also providea corrosion resistant conductivesurface coating on aluminum orplastic substrates.Note: Position Prior toClosing and Torquing BoltsFigure 3: Test Set AssemblyCover Test PlateCompression StopLIGHTNING STRIKE RESISTANCELightning strike testing of CHO-SEAL ® 1298 material has demonstratedsurvivability beyond 5kA/n.The survivability of any system tolightning strike is dependent onspecific flange design. For detailedinformation, contact Chomerics’Applications Department or requestChomerics’ test Report TR34A.Chomerics 49

ORDERING INFORMATIONCHO-SEAL ® 1298 gaskets are available in all standard formsincluding molded, die-cut, and extruded. The material is alsoavailable with Dacron ® fabric, woven wire mesh reinforcementor 3M Nextel for firewall applications.NOTE:DELRIN is a registered trademark of E.I. DuPont de Nemours and Company.DACRON is a registered trademark of Invista.Figure 4: Volume Resistivity of the CHO-SEAL ® 1298 EMIGasket After Salt Fog ExposureCHOMERICS’ CORROSION PROTECTION PUBLICATIONSTest Method CHO-TM100Test Method CHO-TM200Test Method CHO-TM201Test Report CHO-TC001Test Report CHO-TC002Test Report CHO-TR19ATest Report CHO-TR19BTest Report CHO-TR19CTest Report CHO-TR19D S.E.Test Report CHO-TR19E S.E.Test Report CHO-TR19FTest Report CHO-TR30ATest Report CHO-TR34ATest Report CHO-TR34BTest Method for Assessing Galvanic Corrosion Caused Conductive ElastomersShielding Effectiveness Measurements of EMI Gaskets Subjected toSalt Fog ExposureS.E. Measurements of EMI Gaskets and Flange Treatments Subjected toSalt Fog ExposureProduct Evaluation: Acrylic Based Copper Filled Coating in aSalt Fog EnvironmentProduct Evaluation: Carbon Filled TPE Elastomer Corrosion ResistanceCorrosion Resistance of Conductive Elastomers:Silver and Silver-Plated FiltersCorrosion Resistance of Conductive Elastomers:Nickel and Nickel-Coated FiltersCorrosion Resistance of Conductive ElastomersSilver-Plated Aluminum FiltersMeasurements on Various Conductive Elastomers Subjected to SO2 Salt FogMeasurements on CHO-SEAL 1298 Gaskets Subjected to Salt Fog ExposureDetermination of the Corrosion Resistance of CHO-SEAL 1298 ConductiveElastomer Used in Conjunction with CHO-SHIELD 2001 Conductive CoatingEvaluation of CHO-SHIELD 2000 Series Coatings Subjected to Salt Fog ExposureLightning Strike Evaluations of Reinforced, Conductive Airframe SealsFlammability Evaluations of Reinforced, Conductive Airframe SealsChomerics 50

Conductive Elastomer Gasket DesignGasket Junction DesignThe ideal gasketing surface is rigidand recessed to completely housethe gasket. Moreover it should beas conductive as possible. Metalsurfaces mating with the gasketideally should be non-corrosive.Where reaction with the environmentis inevitable, the reactionproducts should be electricallyconductive or easily penetrableby mechanical abrasion. It is herethat many gasket designs fail. Thedesigner could not, or did not treatthe mating surface with the samecare as that given to the selection ofthe gasketing material.By definition, a gasket is necessaryonly where an imperfect surfaceexists. If the junction were perfect,which includes either a solidlywelded closure, or one with matingsurfaces infinitely stiff, perfectly flat,or with infinite conductivity acrossthe junction, no gasket would benecessary. The more imperfect themating surfaces, the more criticalthe function of the gasket. Perfectsurfaces are expen sive. The finalsolution is generally a compromisebetween economics and performance,but it should not be at theexpense of neglecting the design ofthe flange surfaces.The important property that makesa conductive elastomer gasket agood EMI/EMP seal is its ability toprovide good electrical conductivityacross the gasket-flange interface.Generally, the better the conformabilityand conduc tivity, the higherthe shielding effective ness of thegasket. In practice, it has beenfound that surface conductivity ofboth the gasket and the mating surfacesis the single most importantproperty that makes the gasketedseam effective; i.e., the resistancebetween the flange and gasketshould be as low as possible.At this stage of the design everyeffort should be given to choosing aflange that will be as stiff as possibleconsistent with the constructionused and within the other designconstraints.1. Flange MaterialsFlanges are generally made of thesame material as the basic enclosurefor reasons of economy,weldability, strength and resistanceto corrosion. Wherever possible, theflanges should be made of materialswith the highest possible conductivity.It is advisable to add cautionnotes on drawings not to paint theflange mating surfaces. If paint is tobe applied to outside surfaces, besure that the contact surfaces arewell masked before paint is applied,and then cleaned after the maskingtape is removed. If the assem bledunits are subject to paint ing or repaintingin the field, add a cautionarynote in a conspicuous location adjacentto the seal that the seal areasare to be masked before painting.Ordinarily, the higher the conductivityof a material, the more readilyit oxidizes – except for noble metalssuch as gold and silver. Gold isimpervious to oxidation, and silver,although it oxidizes, forms oxidesthat are soft and relatively conductive.Most oxides, however, are hard.Some of the oxide layers remainthin while others build up to substantialthickness in relatively shorttime. These oxides form insulating,or semi-conducting films atthe boundary between the gasketand the flanges. This effect canbe overcome to a degree by usingmaterials that do not oxidize readily,or by coating the surface witha conductive material that is lesssubject to oxidation. Nickel platingis generally recommended foraluminum parts, although tin hasbecome widely accepted. Zinc isprimarily used with steel. Consultthe applicable specifications beforeselecting a finish. A good guide tofinishing EMI shielded flanges foraerospace applications has beenpublished by SAE Committee AE-4(Electromagnetic Compatibility)under the designation ARP 1481.A discus sion of corrosion controlfollows later in this guide.2. Advantages of Grooved DesignsAll elastomer materials are subjectto “Compression Set,” especially ifover compressed. Because flangesurfaces cannot be held uniformlyflat when the bolts are tightened(unless the flanges are infinitelystiff), gaskets tend to overcompressin the areas of the bolts. Propergroove design is required to avoidthis problem of over compression.A groove also provides metal-tometalcontact between the flangemembers, thereby reducing contactresistance across the junction.A single groove will suffice for mostdesigns. Adding a second grooveparallel to the first adds approximately6 dB to the overall performanceof a single-groove design.Adding more grooves beyond thesecond does not increase the gasketingeffectiveness significantly.3. Flange Design ConsiderationsMost designers fight a space limitation,particularly in the vicinity ofthe gasketed seam. Complex fastenersare often required to makethe junctions more compact.The ideal flange includes a groovefor limiting the deflection of agasket. The screw or bolt fastenersare mounted outboard of the gasketto eliminate the need for providinggaskets under the fasteners. A machinedflange and its recom mendedgroove dimensions are shown inFigure 1. The gasket may be an “O”or “D”-shaped gasket, either solidor hollow.Gasket DesignChomerics 51

GDE =2ED = Diameter of WasherW = Uncompressed Diameter of O-RingH = Groove Depth = 0.75-0.90 WG = 1.1 WFigure 1. Machined Flange with Gasket GrooveGSolid conductive O-rings are normallylimited to a deflection of 25percent. Therefore, the minimumcompressed height of the O-ring(also the groove depth) is relatedto the uncompressed height (ordiameter) by the expression H = 0.75W, where W is the uncom presseddiameter. The width of the groove,G, should be equal to 1.1 W. Allowsufficient void in the groove area toprovide for a maximum gasket fillof 97 percent. Conductive elastomergaskets may be thought of as“incompressible fluids.” For this reason,sufficient groove cross sectionalarea must be allowed for the largestcross-sectional area of the gasketwhen tolerances are taken into account.Never allow groove and gaskettolerance accumulations to cause an“over-filled” groove (see gasket tolerancesin section which follows).When a seal is used to isolatepressure environments in additionto EMI, the bottom of the gasketgroove should have a surface finishof 32-64 μin. (RMS) to minimizeleakage along the grooves. Avoidmachining methods that producelongitudinal (circumferential)scratches or chatter marks. Conversely,a surface that is too smoothwill cause the gasket to “roll over”or twist in its groove.The minimum distance from theedge of the groove to the nearestterminal edge, whether this terminalbe the edge of a casting, a change incross section, or a fastening device,HGshould be equal to the groove width,G.Bolts should be located a minimumdistance, E (equal to one-half the diameterof the washer used under thehead of the bolt) from the edge of theflange.Square or rectangular cross sectiongaskets can be used in thesame groove provided sufficient voidis allowed for displacement of theelastomer. A good design practice isnot to allow the height of the gasketto exceed the base width. A better, ora more optimum ratio is a height-towidthratio of one-half. Tall gasketstend to roll over when loaded.The thickness of a flange is governedby the stiffness required to preventexcessive bowing between fastenerpoints. Fewer, but larger bolts,require a thicker flange to preventexcessive deflections. For calculationsof elastic deformation, refer topages 61 to 63.O-shaped and D-shaped gaskets mayalso be used in sheet metal flanges.The gaskets can be retained in a U-channel or Z-retainer, and are deflection-limitedby adjusting the channelor retainer dimensions with respectto gasket height. Suggested retainerconfigurations are shown in Figures2a and 2b.A basic difference between flangesconstructed from sheet metal andthose which are machined fromW HCoverOverlappingSpot WeldsFigure 2a. Shaped Sheet Metal ContainerSheet Metal HousingFigure 2b. Z-Retainer Forms Gasket CavityGF = 1.5 DDGasket CavityF"Z" Retainercastings is that the bolts cannot belocated as close to the edge of thepart when the flange is made of sheetmetal. Note, in Figure 2a, F is recommendedto be 1.5 D, where D is thediameter of the washer.Flat gaskets are ordinarily usedwith sheet metal or machinedflanges as typically illustrated inFigure 3. Bolt holes in the flangesshould be located at least 1.5 timesthe bolt diameter from the edge ofthe flange to prevent tearing whenthe metal is punched.Figure 3. Flat Gasket on Sheet Metal FlangeIf the holes are drilled, the positionof the holes should be not less thanthe thickness of the gasket materialfrom the edge of the flange. If holesmust be placed closer to the edgethan the recommended values, earsor slots should be considered asshown in Figure 4. Holes in flat gasketsshould be treated in a similarmanner.Figure 4. Ears or Slots in SheetMetal Flanges or Flat Gaskets4. Dimensional TolerancesGrooves should be held to a machinedtolerance of ±0.002 in.Holes drilled into machined partsshould be held to within ±0.005 in.with respect to hole location. Locationof punched holes should bewithin ±0.010 in. Sheet metal bendsFtF = tChomerics 52

should be held to +0.030 and –0.000in. Gasket tolerances are given inthe “Selection of Seal Cross Section,”later in this guide.5. Waveguide FlangesThe three concerns for waveguideflanges are to ensure maximumtransfer of electromagnetic energyacross the flange interface to preventRF leakage from the interface, andto maintain pressurization of thewaveguide. Conductive elastomericgaskets provide both an electrical anda seal function. For flat cover flanges,a die-cut sheet gasket (CHO-SEAL1239 material), incorpo rating expandedmetal reinforcement to controlgasket creep into the wave guideopening, provides an excellentseal. Raised lips around the gasketcut-out improve the power handlingand pres sure sealing capability ofthe gasket. Choke flanges are bestsealed with molded circular D-Sectiongaskets, and contact flangeswith molded rec tangular D-gasketsin a suitable groove (both in CHO-SEAL 1212 material).The peak power handling capabilitiesof waveguide flanges arelimited primarily by misalignmentand sharp edges of flanges and/orgaskets. Average power handling islimited by the heating effects causedby contact resistance of the flangegasketinterface (“junction resistance”).CORROSIONAll metals are subject to corrosion.That is, metal has an innate tendencyto react either chemically orelectro chemically with its environmentto form a compound which isstable in the environment.Most electronic packages must bedesigned for one of four generalenvironments:Class A. Controlled EnvironmentTemperature and humidity are controlled.General indoor, habitableexposure.Class B. Uncontrolled EnvironmentTemperature and humidity are notcontrolled. Exposed to humidities ofTable 1: Minimum Finish RequirementsMetalCarbon and AlloySteelCorrosion-ResistantSteelsAluminum 2000 &7000 seriesAluminum 3000,5000, 6000 seriesand cladCopper and CopperAlloysMinimum Finish Requirements for Structural Metals100 percent with occasional wetting.Outdoor exposure or exposurein uncontrolled warehouses.Class C. Marine EnvironmentShipboard exposure or land exposurewithin two miles of salt waterwhere conditions of Class A are notmet.Class D. Space EnvironmentExposure to high vacuum and highradiation.FINISHESTable 1 shows the minimum finishneces sary to arrest chemical corrosionand provide an electricallyconductive surface for the commonmetals of con struction. Onlythe Class A, B, and C en vironmentsare shown in the table becausethe space environment is not acor rosive one (i.e., metals are notgenerally affected by the spaceenvironment).Some metals require finishingbecause they chemically corrode.These are listed in Table 1, andshould be finished in accordancewith the table. To select a properfinish for metals not given in Table1, refer to the material groupingsof Table 2. Adjacent groups inTable 2 are compatible. Anotherexcel lent source of information onENVIRONMENTClass A Class B Class C0.0003 in. cadmium plate0.0005 in. zinc plate0.0003 in. tinNo finish requiredChromate conversioncoat (MIL-DTL-5541F,Type I, Class 3)No finish required, unlessshieldingrequirements are high(see above)0.0005 in. zinc plate0.001 in. zinc0.0005 in. tinNo finish required;0.0005 in. nickel toprevent tarrnishChromate conversioncoat (MIL-DTL-5541F,Type I, Class 3) plusconductive expoxy orurethaneChromate conversioncoat0.003 in. nickel0.001 in. tinNo finish required;0.001 in. nickel toprevent tarnish0.001 in. tinChromate conversioncoat plush conductiveepoxy or urethane0.0003 in. tin 0.0005 in. tin 0.003 in. nickel0.001 in. tinMagnesium 0.0003 in. tin 0.0005 in. tin 0.001 in. tincorrosion-compatible finishes forEMI shielded flanges is ARP 1481,developed and published by SAE’sCommittee AE-4 (ElectromagneticCompatibility).When a finish is required to maketwo mating metals compatible,finish the metal which is found inthe lower numbered grouping ofTable 2. Metals given in Table 2 will,because of their inherent corrodibility,already be finished and thefinish metal will be subject to thesame rule.For example, to couple metalsseparated by two or more groups(e.g., 4 to 2), find a finish which appearsin Group 3 and 4. The Group3 metal should be plated onto theGroup 2 metal to make metals 2 and4 compatible. The reason for this is,if the finish metal breaks down, oris porous, its area will be large incomparison to the exposed area ofthe Group 2 metal, and the galvaniccorrosion will be less.On aluminum, chromate conversioncoatings (such as Iridite) can beconsidered as conductive finishes.MIL-DTL-5541F, Type I, Class 3conversion coatings are requiredto have less than 200 milliohms resistancewhen measured at 200 psicontact pressure after 168 hours ofexposure to a 5 percent salt spray.Gasket DesignChomerics 53

Table 2: Metals CompatibilityRecommended MIL-DTL-5541F,Type I, Class 3 coatings are Alodine600, or Alodine 1200 and 1200Sdipped.Organic FinishesOrganic finishes have been usedwith a great deal of success toprevent corrosion. Many organicfinishes can be used, but none willbe effective unless properly applied.The following procedure has beenused with no traces of corrosionafter 240 hours of MIL-STD-810Bsalt fog testing.Aluminum panels are cleaned witha 20% solution of sodium hydroxideand then chromate conversioncoated per MIL-DTL-5541F, Type I,Class 3 (immersion process). Theconversion coated panels are thencoated with MIL-C-46168 Type 2urethane coating, except in theareas where contact is required. Formaximum protection of aluminumflanges, a CHO-SHIELD 2000 seriesconductive coating and CHO-SEAL1298 conductive elastomer gasketmaterial are recommended. For additionalinformation, refer to DesignGuides for Corrosion Control, page55.The finish coat can be any suitableurethane coating that is compatiblewith the MIL-C-46168 coating. It isMetals CompatibilityGroupMetal Groupings*1 Gold – Platinum – Gold/Platinum Alloys – Rhodium – Graphite – Palladium – Silver– Silver Alloys – Titanium – Silver Filled Elastomers – Silver Filled Coatings2 Rhodium – Graphite – Palladium – Silver – Silver Alloys – Titanium – Nickel – Monel– Cobalt –Nickel and Cobalt Alloys – Nickel Copper Alloys – AISI 300 SeriesSteels – A286 Steel –Silver Filled Elastomers – Silver Filled Coatings3 Titanium – Nickel – Monel – Cobalt – Nickel and Cobalt Alloys – Nickel CopperAlloys – Copper –Bronze – Brass – Copper Alloys – Silver Solder – CommercialYellow Brass and Bronze – Leaded Brass and Bronze – Naval Brass – Steels AISI300 Series, 451, 440, AM 355 and PH hardened – Chromium Plate – Tungsten– Molybdenum – Certain Silver Filled Elastomers4 Leaded Brass and Bronze – Naval Brass – Steels AISI 431, 440, 410, 416, 420, AM355 and PH hardened – Chromium Plate – Tungsten – Molybdenum – Tin-Indium– Tin Lead Solder –Lead – Lead Tin Solder – Aluminum 2000 and 7000 Series– Alloy and Carbon Steel –Certain Silver Filled Elastomers – CHO-SHIELD 2000Series Coatings5 Chromium Plate – Tungsten – Molybdenum – Steel AISI 410, 416, 420, Alloy andCarbon –Tin – Indium – Tin Lead Solder – Lead – Lead Tin Solder – Aluminum– All Aluminum Alloys – Cadmium – Zinc – Galvanized Steel – Beryllium – ZincBase Castings6 Magnesium – Tin*Each of these groups overlap, making it possible to safely use materials from adjacent groups.important to note that test specimenswithout the MIL-C-46168coating will show some signs ofcorrosion, while coated test specimenswill show no traces of corrosion.CHO-SHIELD ® 2000Series CoatingsWhen using CHO-SHIELD 2000 seriesconductive urethane coatings itis important to prepare the surfaceto attain maximum adhesion. Theeasily mixed three-component systemallows minimum waste with noweighing of components, thus eliminatingweighing errors. Because ofthe filler loading of the 2000 seriescoatings, it is recommended thatan air agitator cup be incorporatedinto the spray system to keep theconductive particles in suspensionduring the spraying sequence. It isrecom mended that approximately7 mils of wet coating be applied.This thickness can be achieved byspraying multiple passes, with a tenminute wait between passes.A 7-mil wet film coating will yield adry film thickness of 4 mils, whichis the minimum thickness requiredto attain the necessary corrosionand electrical values referencedin Chomerics’ Technical Bulletin30. The coating thickness playsan important role in the electricaland corrosion properties. Thinnercoatings of 1-3 mils do not exhibitthe corrosion resistance of 4-5 milcoatings.The coating will be smooth to thetouch when cured. It is recommendedthat the coating be cured atroom temperature for 2 hours followedby 250°F +/-10°F for one-halfhour whenever possible. Alternatecure cycles are available, but withsignificant differences in corrosionand electrical properties. Twoalternate cure schedules are twohours at room temperature followedby 150°F for two hours, or 7 days atroom temperature.Full electrical properties areachieved at room temperature after7 days. It should be noted that the250°F cure cycle reflects theultimate in corrosion resistanceproperties. The 150°F/2 hour androom temperature/7 day cures willprovide less corrosion resistancethan the 250°F cure, but are wellwithin the specification noted inTechnical Bulletin 30.1091 PrimerBecause of the sensitivity of surfacepreparation on certain substratesand the availability of equipment toperform the etching of aluminumprior to the conversion coating,Chomerics has introduced 1091primer, which is an adhesion promoterfor CHO-SHIELD 2000 seriescoatings. When used in conjunctionwith an alkaline etch or chemicalconversion coating per MIL-DTL-5541F, Type I, Class 3, the 1091primer will provide maximum adhesionwhen correctly applied. (SeeTech nical Bulletin 31.) This primeris recommended only for the 2000series coatings on properly treatedaluminum and is not recommendedfor composites.For further assistance on the applicationof CHO-SHIELD 2000 seriescoatings on other metallic andnon-metallic substrates, contactChomerics’ Applications EngineeringDepartment.Chomerics 54

Galvanic CorrosionThe most common corrosionconcern related to EMI gaskets isgalvanic corrosion. For galvaniccorrosion to occur, a unique set ofconditions must exist: two metalscapable of generating a voltagebetween them (any two unlike metalswill do), electrically joined bya current path, and immersed in afluid capable of dissolving the lessnoble of the two (an electrolyte). Insummary, the conditions of a batterymust exist. When these conditionsdo exist, current will flow andthe extent of corrosion which willoccur will be directly related to thetotal amount of current the galvaniccell produces.When an EMI gasket is placedbetween two metal flanges, thefirst condition is generally satisfiedbecause the flanges will probablynot be made of the same metal asthe gasket (most flanges are aluminumor steel, and most EMI gasketscontain Monel, silver, tin, etc.).The second condition is satisfiedby the inherent conductivity of theEMI gasket. The last condition couldbe realized when the electronicpackage is placed in service, wheresalt spray or atmos pheric humidity,if allowed to collect at the flange/gasket interface, can provide theelectrolyte for the solution of ions.Many users of EMI gaskets selectMonel mesh or Monel wire-filledmaterials because they are oftendescribed as “corrosion-resistant.”Actually, they are only corrosionresistantin the sense that they donot readily oxidize over time, even inthe presence of moisture. However,in terms of electrochemical compatibilitywith aluminum flanges,Monel is extremely active and itsuse requires extensive edge sealingand flange finish treatment toprevent galvanic corrosion. Mostgalvanic tables do not include Monel,because it is not a commonlyused structural metal. The galvanictable given in MIL-STD-1250 doesinclude Monel, and shows it to havea 0.6 volt potential difference withrespect to aluminum – or almostthe same as silver.A common misconception is that allsilver-bearing conductive elastomersbehave galvanically as silver.Experiments designed to show thegalvanic effects of silver-filled elastomergaskets in aluminum flangeshave shown less corrosion thanpredicted. Silver-plated-aluminumfilled elastomers exhibit the leasttraces of galvanic corrosion and silver-plated-copperfilled elastomersexhibit more. (See Table 3).Tables of galvanic potential do notaccurately predict the corrosivity ofmetal-filled conductive elastomersbecause of the composite natureof these materials. Also, thesetables do not measure directly twoimportant aspects of conductiveelastomer “corrosion resistance”:1) the corrosion of the matingmetal flange and 2) the retention ofconductivity by the elastomer afterexposure to a corrosive environment.Instead of using a table of galvanicpotentials, the corrosion causedby different conductive elastomerswas determined directly by measuringthe weight loss of an aluminumcoupon in contact with the conductiveelastomer (after exposure to asalt fog environ ment). The electricalstability of the elastomer was determinedby measuring its resistancebefore and after exposure.Figure 5a describes the test fixturethat was used. Figure 5b shows thealuminum weight loss results forseveral different silver-filled conductiveelastomers. The aluminumweight loss shows a two order ofmagnitude difference be tween theleast corrosive (1298 silver-platedaluminum)and most corrosive(1215 silver-plated- copper) filledelastomers. For silver-containingelastomers, the filler substrate thatthe silver is plated on is the singlemost important factor in determiningthe corrosion caused by theconductive elastomerFigure 5c shows the weight lossresults for nickel and carbon-filledelastomers compared to 1298. Thenickel-filled materials are actuallyTable 3: Corrosion Potentials for Metals andGasket MaterialsCorrosion Potentials of Various Metalsand EMI Gasket Materials(in 5% NaCl at 21ºC,after 15 minutes immersion)MaterialEcorr vs. SCE*(Millivolts)Pure Silver –25Silver-filled elastomer –50Monel mesh –125Silver-plated-copper filledelastomerSilver-plated-aluminum filledelastomer–190–200Copper –244Nickel –250Tin-plated Beryllium-copper –440Tin-plated copper-clad steelmesh–440Aluminum* (1100) –730Silver-plated-aluminum filledelastomer (die-cut edge)–740*Standard Calamel Electrode. Aluminum Alloysapproximately –700 to –840 mV vs. SCE in 3% NaCl.Mansfield, F. and Kenkel, J.V., “Laboratory Studies ofGalvanic Corrosion of Aluminum Alloys,” Galvanic andPitting Corrosion – Field and Lab Studies, ASTM STP576, 1976, pp. 20-47.more corrosive than the silverplated-aluminumfilled elas tomers.The carbon-filled materials areextremely corrosive.Figure 5d compares the electricalstability of several conductive elastomersbefore and after salt fog exposure.In general, silver-containingelastomers are more electricallystable in a salt fog environmentthan nickel-containing elastomers.Design Guides forCorrosion ControlThe foregoing discussion is notintended to suggest that corrosionshould be of no concern whenflanges are sealed with silver-bearingconductive elastomers. Rather,corrosion control by and largepresents the same problem whetherthe gasket is silver-filled, Monelwire- filled, or tin-plated. Furthermore,the designer must understandthe factors which promote galvanicactivity and strive to keep them atsafe levels. By “safe”, it should berecognized that some corrosion islikely to occur (and may be general-Gasket DesignChomerics 55

ly tolerable) at the outer (unsealed)edges of a flange after long-termexposure to salt-fog environments.This is especially true if proper attentionhas not been given to flangeNon-ConductiveSealing GasketFigure 5d Volume Resistivity (mohm-cm) ofConductive Elastomers Before and After168 hr. Salt Fog Exposure 1052.2200BeforeAfter445.1Volume Resistivity (mohm-cm)150100500Non-ConductiveSealing GasketUpper Delrin BlockConductive GasketAluminum AlloyCouponWeight Loss (mg)Weight Loss (mg)LowerDelrin Block30050040302010Figure 5a Test Fixture0

9. Select proper protective finishes.The definition of a “safe“ level ofgalvanic activity must clearly beexpanded to include the requirementsof the design. If all traces ofcorrosion must be prevented (e.g.,airframe applications) the structuremust be properly finished or mustbe made of materials which will notcorrode in the use environment.In these cases, the outside edgesof EMI-gasketed flanges mightalso require peripheral sealing asdefined in MIL-STD-1250, MIL-STD-889 or MIL-STD-454. MIL-STD-1250deserves special mention. Althoughit was developed many years priorto the availability of CHO-SEAL 1298conductive elastomer and CHO-SHIELD 2000 series conductivecoatings, it offers the followinguseful corrosion control methodsapplicable to electronic enclosures:1. Bonds made by conductivegaskets or adhesives, and involvingdissimilar contact, shall be sealedwith organic sealant.2. When conductive gaskets areused, provision shall be made in designfor environmental and electromagneticseal. Where practical, acombination gasket with conductivemetal encased in resin or elastomershall be preferred.3. Attention is drawn to possiblemoisture retention when spongeelastomers are used.4. Because of the serious loss inconductivity caused by corrosion,special precautions such as environmentalseals or external sealantbead shall be taken when wiremesh gaskets of Monel or silver areused in conjunction with aluminumor magnesium.5. Cut or machined edges oflaminated, molded, or filled plasticsshall be sealed with imperviousmaterials.6. Materials that “wick” or arehygroscopic (like sponge core meshgaskets) shall not be used.7. In addition to suitability for theintended application, nonmetallicmaterials shall be selected whichhave the following characteristics:a. Low moisture absorption;b. Resistance to fungi andmicrobial attack;c. Stability throughout thetemperature range;d. Freedom from outgassing;e. Compatibility with othermaterials in the assembly;f. Resistance to flame andarc;g. For outdoor applications,ability to withstandweathering.Selection ofSeal Cross SectionSelection of the proper conductiveelastomer gasket cross section islargely one of application, compromise,and experience with similardesigns used in the past. Somegeneral rules, however, can be establishedas initial design guidelinesin selecting the class of gasket to beused.1. Flat GasketsWhen using flat gaskets, care mustbe taken not to locate holes closerto the edge than the thickness of thegasket, or to cut a web narrowerthan the gasket thickness.This is not to be confused with thecriteria for punching holes in sheetmetal parts discussed earlier.Keep in mind also that flat gasketsshould be deflected typically 10 percent,compared with 15 to 18 percentfor molded and solid extrudedgaskets and 50% inside diameter forhollow gaskets. Standard thicknessesfor flat gaskets are 0.020, 0.032,0.045, 0.062, 0.093 and 0.125 in. (seeGeneral Tolerances, Table 4.)Where possible, the flange shouldbe bent outward so that the screwsor bolts do not penetrate the shieldedcompartment (see Figure 9a). Ifthe flange must be bent inward tosave space, the holes in the gasketmust fit snugly around the threadsof the bolts to prevent leakage alongthe threads and directly into thecompartment. This calls for closelytoleranced holes and accurate registrationbetween the holes in theflange and the holes in the gasket,and would require machined dies(rather than rule dies) to producethe gasket. An alternate solutioncan be achieved by adding an EMIseal under the heads of bolts penetratingthe enclosure, or by using aninsert similar to an acorn nut thathas been inserted in the flange andflared to make the joint RF-tight.“Blind nuts” can also be welded orattached with a conductive epoxyadhesive (see Figure 9b).2. Shaped or Molded GasketsFigure 9a. External Bolting Prevents EMI LeakageFigure 9b. Insert Pressed-In and Flared MakesEMI Tight Joint (Alternate: Weld or Cement withConductive Epoxy)Groove designs for O- or D-shapedconfigurations are effective becausegasket deflection can be controlledand larger deflections can be accommodated.O-ring cross sectionsare preferred because they can bedeflected more easily under a givenload. D-shapes or rectangular crosssections are excellent for retrofitapplications because they can bemade to accommodate almost anygroove cross section. Groove designsalso provide metal-to-metalflange contact for superior shielding,and require fewer fasteners,thereby minimizing the numberof paths where direct leakage canoccur.Fasteners should be located suchthat pressure distribution is uniformat the corners (see Figure 10).3. Hollow GasketsHollow gasket configurations arevery useful when large gaps areGasket DesignChomerics 57

XFigure 10. Fastener Location Near Cornersencountered, or where low closureforces are required. Hollow gasketsare often less expensive, and theycan be obtained with or without attachmenttabs. Hollow gaskets withtabs are referred to in the text andin the tables as “P-gaskets”. Theminimum wall thickness of hollowgaskets is 0.020 in. depending onmaterial. Contact Chomerics’ ApplicationsDepartment for details.Hollow gaskets will compensate fora large lack of uniformity betweenmating surfaces because they canbe compressed to the point of eliminatingthe hollow area.4. Compression LimitsWhen compression cannot be controlled,compression stops shouldbe provided to prevent gasket rupturecaused by over-compression.Grooves provide built-in compressionstops. Figure 11 gives nominalrecom mended compression rangesØWX/2Figure 11. Gasket Deflection RangesWHX/2Xfor CHO-SEAL and CHO-SIL materials,assuming standard tolerances.5. ElongationThe tensile strength of conductiveelastomer gaskets is not high. It isgood practice to limit elongation toless than 10 percent.6. SplicingWhen grooves are provided for gasketcontainment, two approachesare possible. A custom gasket canbe molded in one piece and placedinto the desired groove, or a stripgasket can be spliced to length andfitted to the groove. To properlyseat a spliced solid “O” cross sectiongasket, the inner radius of thegroove at the corners must be equalto or greater than 1.5 times thegasket cross section width. Othercross sections need greater innerradius and may not be practicaldue to twisting when bent aroundcorners. Splices can be simplybutted (with no adhesive) or bondedwith a conductive or non-conductivecompound. If it has been decidedthat a spliced gasket will provide asatisfactory seal, the decision betweensplicing and molding shouldbe based on cost, flash and tolerance.When a standard extrusionis available, splicing is generallyrecommended. For custom extrusions,splicing is generally morecost effective in quantities over 500feet.Deflection Deflection Deflection DeflectionRange ØW Range H Range T Range A ØB0.007-0.018 0.070 0.005-0.014 0.068 0.001-0.003 0.020 0.020-0.080 0.200 0.080(0.178-0.457) (1.778) (0.127-0.356) (1.727) (0.025-0.076) (0.508) (0.508-2.032) (5.08) (2.032)0.010-0.026 0.103 0.007-0.018 0.089 0.002-0.005 0.032 0.025-0.125 0.250 0.125(0.254-0.660) (2.616) (0.178-0.457) (2.261) (0.051-0.127) (0.813) (0.635-3.175) (6.35) (3.175)0.013-0.031 0.125 0.010-0.026 0.131 0.003-0.009 0.062 0.036-0.255 0.360 0.255(0.330-0.787) (3.175) (0.254-0.660) (3.327) 0.076-0.229) (1.575) (0.914-6.477) (9.144) (6.477)0.014-0.035 0.139 0.012-0.031 0.156 0.005-0.014 0.093(0.356-0.889) (3.531) (0.305-0.787) (3.962) (0.127-0.356) (2.362)0.014-0.035 0.175(0.356-0.889) (4.445)T(mm dimensions in parentheses)AØB7. Gasket Limitations Imposedby Manufacturing MethodsCurrent manufacturing technologylimits conductive elastomer gasketconfigurations to the followingdimensions and shapes :■ Die-cut PartsMaximum Overall Size: 32 in. long x32 in. wide x 0.125 in. thick (81 cm x81 cm x 3.18 mm)Minimum Cross Section: Width-tothicknessratio 1:1 (width is not to beless than the thickness of the gasket).■ Molded PartsCurrently available in any solidcross section, but not less than0.040 in. in diameter. The outer dimensionsof the gasket are limitedto 34 inches in any direction. Largerparts can be made by splicing.Molded parts will include a smallamount of flash (0.008 in. width and0.005 in. thickness, maximum).■ Extruded PartsNo limitation on length. Minimumsolid cross-section is limited to0.028 in. extrusions. Wall thicknessof hollow extrusions varies with materialbut 0.020 in. can be achievedwith most materials (S6308, 1215,1273).8. General TolerancesTable 4 provides general tolerancesfor conductive elastomer gaskets. Itis important to note that all flat diecut,molded, and extruded gasketsare subject to free-state variationin the unrestrained condition. Theuse of inspection fixtures to verifyconformance of finished parts iscommon and recommended whereappropriate.Also note that “Overall Dimensions”for flat die-cut gaskets and moldedgaskets includes any feature-tofeaturedimensions (e.g., edge-toedge,edge-to-hole, hole-to-hole).9. Gasket Cross SectionBased on Junction GapsGasket geometry is largely determinedby the largest gap allowedto exist in the junction. Sheet metalenclosures will have larger varia-Chomerics 58

tions than machined or die castings.The ultimate choice in allowablegap tolerance is a compromisebetween cost, perfor mance and thereliability required during the life ofthe device. When a value analysisis conducted, it should be made ofthe entire junction, including themachining required, special handling,treatment of the surfaces andother factors required to make thejunction functional. Often, the gasketis the least expen sive item, andcontributes to cost-effectiveness byallowing loosely-toleranced flangesto be made EMI-tight.The maximum gap allowed to existin a junction is generally determinedby the minimum electricalperfor mance expected of the seal.A secondary consideration must begiven to the barrier as a pressureseal if gas pressures of significantmagni tude are expected. The gasketwill blow out if the pressure is toohigh for the gap.The minimum gap allowed in thejunction is determined by the allowablesqueeze that can be toleratedby the gasket material. Deflectionof conductive elastomer gaskets isgiven in Figure 11. Flat gaskets maybe deflected as much as 6-10 percent(nominal), depending on initialthickness and applied force. O-shaped and D-shaped gaskets arenormally deflected 10 to 25 percent;however, greater deflections canbe achieved by manipulating crosssection configuration.Determination of the exact gasketthickness is a complex probleminvolving electrical performance,flange characteristics, fastenerspacing and the properties of thegasket material. However, an initialestimate of the necessary thicknessof a noncontained gasket canbe determined by multiplying thedifference in the expected minimumand maximum flange gaps by afactor of 4, as illustrated in Figure12. A more detailed discussion, anda more accurate determination ofgasket performance under loadedflange conditions, can be found inthe Fastener Requirements section.G max G min t ot O = 4 (G max - G min)(t O = Original thickness of gasket)Gasket DesignFigure 12. Gasket Deflection Along a FlangeTable 4. General TolerancesFLAT DIE-CUT GASKETSinch (mm)Overall DimensionsTolerance≤10 (254) ±0.010 (0.25)>10 to ≤15 (254 to 381) ±0.020 (0.51)>15 (>381) ±0.20% Nom. Dim.Thickness0.020 (0.51) ±0.004 (0.10)0.032 (0.81) ±0.005 (0.13)0.045 (1.14) ±0.006 (0.15)0.062 (1.57) ±0.007 (0.18)0.093 (2.36) ±0.010 (0.25)0.125 (3.18) ±0.010 (0.25)>0.125 (>3.18) Contact a ChomericsApplications or SalesEngineerHole Diameters>0.060 (1.52) dia. if sheet thickness is...≤0.062 (1.57) ±0.005 (0.13)>0.062 (1.57) ±0.008 (0.20)Location of Hole Center ±0.007 (0.18)MOLDED GASKETSinch (mm)ToleranceOverall Dimensions0.100 to 1.500 (2.54 to 38.10) ±0.010 (0.25)1.501 to 2.500 (38.13 to 63.50) ±0.015 (0.38)2.501 to 4.500 (63.53 to 114.30) ±0.020 (0.51)4.501 to 7.000 (114.33 to 177.80) ±0.025 (0.64)>7.000 (>177.80) ±0.35% Nom. Dim.Cross Section0.040 to 0.069 (1.02 to 1.75) ±0.003 (0.08)0.070 to 0.100 (1.78 to 2.54) ±0.004 (0.11)0.101 to 0.200 (2.57 to 5.08) ±0.005 (0.13)0.201 to 0.350 (5.11 to 8.89) ±0.008 (0.20)EXTRUDED STRIP GASKETSinch (mm)ToleranceCut Length 30.000 (762) ±0.20% Nom.Dim.Cross Section< 0.200 (5.08) ±0.005 (0.13)0.200-0.349 (5.08-8.86) ±0.008 (0.20)0.350-0.500 (8.89-12.70) ±0.010 (0.25)>0.500 (12.70) ±3% Nom. Dim.Chomerics 59

Gasket Mounting ChoicesOur various EMI gasket mounting techniques offer designers cost-effective choices in both materials andassembly. These options offer aesthetic choices and accommodate packaging requirements such as tightspaces, weight limits, housing materials and assembly costs. Most Chomerics gaskets attach using easilyrepairable systems. Our Applications Engineering Department or your local Chomerics representative canprovide full details on EMI gasket mounting. The most common systems are shown here with the availableshielding products.Pressure-Sensitive AdhesiveQuick, efficient attachment strip■ Conductive Elastomers■ SOFT-SHIELD ® ■ POLASHEET ®■ SPRING-LINE ® ■ POLASTRIP ®Friction Fit in a GroovePrevents over-deflection of gasketRetaining groove required■ Conductive ■ MESH STRIPElastomers ■ POLASTRIP ®■ SOFT-SHIELD ® ■ SPRINGMESH ®Adhesive CompoundsConductive or non-conductivespot bonding■ Conductive Elastomers■ MESH STRIPRobotically Dispensed Form-in-Place Conductive ElastomerChomerics’ CHOFORM ® automatedtechnology applies high quality conductiveelastomer gaskets to metalor plastic housings. Manufacturingoptions include Chomerics facilities,authorized Application Partners,and turnkey systems.Friction Fit on TangsAccommodates thin walls,intricate shapes■ Conductive ElastomersSpacer GasketsFully customized, integralconductive elastomer and plasticspacer provide economical EMIshielding and grounding in smallenclosures. Locator pins ensureaccurate and easy installation,manually or robotically.Metal ClipsRivets/ScrewsTeeth bite through painted panels Require integral compression stopsRequire knife edge mounting flange Require mounting holes on flange■ ■ Conductive ■Conductive ElastomersSHIELDMESH ®®Elastomers■ ■METALKLIPCOMBO STRIP■ SPRING-LINE■ SPRING-LINE ®FramesExtruded aluminum framesand strips add rigidity. Built-incompression stops for rivets andscrews.■ Conductive Elastomers■ MESH STRIPChomerics 60

FASTENER REQUIREMENTS1. Applied ForceMost applications do not requiremore than 100 psi (0.69 MPa) toachieve an effec tive EMI seal.Wave guide flanges often provide tentimes this amount. Hollow stripsrequire less than 10 pounds per in.Com pres sion deflec tion data formany shapes, sizes and materialsis included in the Performance Datasection of this Design Guide.The force required at the point ofleast pressure, generally midwaybetween fasteners, can be obtainedby using a large number of smallfasteners spaced closely together.Alternatively, fasteners can bespaced further apart by using stifferflanges and larger diameter bolts.Sheet metal parts require more fastenersper unit length than castingsbecause they lack stiffness.To calculate average applied forcerequired, refer to load-deflectioncurves for specific gasket materialsand cross sections (see PerformanceData).2. Fastener Sizes and SpacingFastener spacing should be determinedfirst. As a general rule,fasteners should not be spacedmore than 2.0 inches (50 mm) apartfor stiff flanges, and 0.75 inch (19mm) apart for sheet metal if highlevels of shielding are required. Anexception to the rule is the spacingbetween fasteners found in largecabinet doors, which may vary from3 inches (76.02 mm) between centersto single fasteners (i.e., doorlatches). The larger spacings arecompen sated for by stiffer flangesections, very large gaskets, and/orsome reduction in electrical performancerequirements.The force per bolt is determinedby dividing the total closure forceby the number of bolts. Select afastener with a stress value safelybelow the allowable stress of thefastener.3. Flange DeflectionThe flange deflection betweenfasteners is a complex probleminvolving the geometry of the flangeand the asymmetrical applicationof forces in two directions. The onedimensionalsolution, which treatsthe flange as a simple beam on anelastic foundation, is much easier toanalyze and gives a good first orderapproximation of the spacings requiredbetween fasteners, becausemost EMI gaskets are sand wichedbetween compliant flangesVariation in applied forces betweenfasteners can be limited to ±10percent by adjusting the constantsof the flange such thatβD = 2,where√ 4 Kβ =4 E ƒI ƒk = foundation modulus of the sealE ƒ= the modulus of elasticity of the flangeI ƒ= the moment of inertia of the flangeand seald = spacing between fastenersThe modulus of elasticity (E f ) forsteel is typically 3 x 10 7 . The modulusfor aluminum is typically 1 x 10 7 ,and for brass it is about 1.4 x 10 7 .The foundation modulus (k) of sealsis typically 10,000 to 15,000 psi.The moment of inertia (l f) of rectangularsections, for example, may beobtained from the following expression2 : I f= bh 312whereb = the width of the flange in contact withthe gasket (inches) andh = the thickness of the flange (inches).ExampleCalculate the bolt spacings for flanges with arectangular cross-section, such as shown inFigure 12, whereReferences1. Galagan, Steven, Designing Flanges and Seals for Low EMI, Microwaves, December 1966.2. Roark, R. J., Formulas for Stress and Strain, McGraw-Hill, 4th Ed., p. 74.h is the thickness of the flange.b is the width of the flange.d is the spacing between fasteners.hbFigure 12. Bolt Spacings for FlangesAssume the flange is to be made ofaluminum.To maintain a pressure distributionbetween bolts of less than ±10percent, ßd must be equal to 2(see Figure 13 and discussion). And - xN = 0N - 1Array Factor2.42.22.01.81.61.41.21.00.80.60.40.20Ð0.2Ð0.4Figure 13. Array Factor vs. SpacingN - 1Σβpy =2kn - 0d8 7 6 5 4 3 2 1 0 1 2 3 4 5 6 7 8(-) x (+)A nβd-βx§d = 1d = 2d = 3d = 4d = Assume an average foundationmodulus (k) of 12,500 psi for theseal. If the actual modulus is known(stress divided by strain), substitutethat value instead.The bolt spacings for aluminumflanges for various thicknesses andwidths have been calculated for theprevious example and are shown inFigure 14.The previous example does not takeinto account the additional stiffnesscontributed by the box to which theflange is attached, so the resultsare somewhat conservative.Actual deflection vs. distance betweenfasteners may be computedfrom the following expression:Gasket DesignChomerics 61

where p is the force applied by the fastener,and β and k are the con stants of the flangeas determined previously. N represents thenumber of bolts in the array.The array factor denoted by thesummation sign adds the contributionof each fastener in the array.The array factor for various boltspacings (βd) is shown in Figure 13.Although any value can be selectedfor βd, a practical compromise betweendeflection, bolt spacing andelectrical performance is to select abolt spacing which yields a value βdequal to 2.Fastener Spacing, d (inches)2.82.62.42.22.01.81.61.41.21.00.80.60.40.2Calculated for aluminum flanges with arectangular cross section where:Ef = 10,000,000k = 12,000 (average modulus forconductive silicones)h = thicknessh = 1/4"h = 3/32"h = 1/16"h = 1/32"0.00.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0Width of Flange, b (inches)Figure 14. Fastener SpacingTable 5: Bolt/Spacing RecommendationsSCREWSIZECenterline toCenterline (in.)Thickness(in.)widely used fastening devices. Theapproximate torque required toapply adequate force for mild steelbolts is shown in Table 5.These values are approximateand will be affected by the type oflubricants used (if any), plating, thetype of washers used, the class andfinish of the threads, and numerousother factors.The final torque applied to the fastenersduring assembly should be133 percent of the design value toovercome the effect of stress-relaxation.When torqued to this value,the gasket will relax over a periodof time and then settle to the designvalue.Torque may be converted to tensionin the bolts by applying the formulaMax. Torque to Prevent Strippingfor UNC-2A Thread(in.-lbs.)#2 3⁄8 0.062 4.5#4 3⁄4 0.125 10.0#6 1 0.125 21.0#8 11⁄4 0.156 37.5#10 13⁄8 0.156 42.5TorqueTension =0.2 x Bolt Dia.must be taken of the finish specifiedto minimize galvanic corrosion.Thermal conductivity of high tensilestrength hardware is lower thanmost materials used in electro-mechanicalpackaging today, so thatthe enclosure expands faster thanthe hardware and usually helps toTable 6: Recommended Torque ValuesRECOMMENDED TORQUE VALUESFOR MILD STEEL BOLTSSizeThreadsper in.Max. RecommendedTorque(in.-lbs)Tension*(lbs.)BasicPitch Dia.(inches)#4 40 4¾ 0.095848 6 0.0985#5 40 7 0.108844 8½ 0.1102#6 32 8¾ 0.117740 11 0.1218#8 32 18 0.1437For βd = 2, the flange deflectionfluctuates by ±10 percent. Minimumdeflection occurs midway betweenfasteners and is 20 percent lessthan the deflection directly underthe fasteners. The variation in deflectionis approximately sinusoidal.Table 5 lists a few recommendationsfor bolts and bolt spacings invarious thin cross section aluminumflanges.Bolt spacings for waveguide flangesare fixed by Military and EIA Standards.Waveguide flanges normallyhave bolts located in the middle ofthe long dimension of the flangebecause the flow of current is mostintense at this point.4. Common FastenersMany different types of fastenersare available, but bolts are the mostFrequently the general value of 0.2for the coefficient of friction canresult in torque and bolt estimateswhich may be seriously in error.Excessive bolt preload may lead toRF leakage. Therefore, if lubricantsare used for any reason, refer to theliterature for the proper coefficientvalues to be applied.In soft materials, such as aluminum,magnesium and insulatingmaterials, inserts should beprovided if the threads are “workingthreads.” A thread is considered a“working thread” if it will be assembledand disassembled ten ormore times.Torque loss caused by elongationof stainless steel fasteners shouldalso be considered. High tensilestrength hardware is advised whenthis becomes a problem, but care36 20 0.1460#10 24 23 0.162932 32 0.16971/4” 20 80 1840 0.217528 100 2200 0.22685/16” 18 140 2530 0.276424 150 2630 0.28543/8” 16 250 3740 0.334424 275 3950 0.34797/16” 14 400 5110 0.391120 425 5250 0.40501/2” 13 550 6110 0.450020 575 6150 0.46759/16” 12 725 7130 0.508418 800 7600 0.52645/8” 11 1250 11,040 0.566018 1400 11,880 0.5889Torque*Tension =0.2 x Bolt Dia. ffBasic Pitch DiameterChomerics 62

tighten the seal. Should the equipmentbe subjected to low temperaturesfor long periods of time, thebolts may require tightening in thefield, or can be pretightened in thefactory under similar conditions.Under shock and vibration, a stackup of a flat washer, split helicallockwasher and nut are the leastreliable, partly because of elongationof the stainless steel fasteners,which causes the initial loosening.The process is continued undershock and vibration conditions.Elastic stop nuts and locking insertsinstalled in tapped holes haveproven to be more reliable undershock and vibration conditions,but they cost more and are moreexpensive to assemble.5. Electrical Performance as aFunction of Fastener SpacingThe electrical performance (shieldingeffectiveness) provided by agasket sandwiched between twoflanges and fastened by boltsspaced “d” distance apart is equivalentto the shielding effectivenessobtained by applying a pressurewhich is the arithmetic mean of themaximum and minimum pressureapplied to the gasket under thecondition that the spacing betweenfasteners is considerably less thana half wave length. For bolt spacingsequal to or approaching one-halfwavelength at the highest operatingfrequency being considered, theshielding effective ness at thepoint of least pressure is the governingvalue.For example, assume that a gasketis sandwiched between two flangeswhich, when fastened together withbolts, have a value of βd equal to 2.Figure 13 shows that a value of βd= 2 represents a deflection changeof ±10 percent about the meandeflection point. Because appliedpressure is directly proportionalto deflection, the applied pressurealso varies by ±10 percent.Shielding effectiveness values fortypical silver-plated-copper filled,die-cut gaskets as a function ofapplied pressure are shown inShielding Effectiveness (dB)Figure 15. Shielding Effectiveness vs.Applied PressureFigure 15. The curves show thatthe shielding effectiveness variesappreciably with applied pressure,and changes as a function of thetype of field considered. Plane waveattenuation, for example, is moresensitive to applied pressure thanelectric or magnetic fields.Thus, in determining the performanceto be expected from a junction,find the value for an appliedpressure which is 10 percent less(for βd = 2) than the value exertedby the bolts directly adjacent to thegasket. For example, examine aportion of a typical gasket performancecurve as shown in Figure 16.The average shielding effectivenessof the gasketed seam is a functionof the mean applied pressure, p m.For spacings which approach or areequal to one-half wavelength, theshielding effectiveness is a functionShielding Effectiveness1501005000Max.MeanMin.Electric Fields200Applied Pressure (psi)p 1 p m p 210 kHz to 10 MHz1 GHz18 MHzPlane WavesMagnetic Fields400 MHz10 GHz200 kHz100 kHz14 kHz400p 1 = Minimum Pressurep m = Mean Pressurep 2 = Maximum PressurePressureFigure 16. Typical Gasket Performance Curveof the minimum pressure, p1. Therefore,the applied pressure must be20 percent higher to achieve therequired performance. For thiscondition, the space between thefasteners can be considered to bea slot antenna loaded with a lossydielectric. If the slot is completelyfilled, then the applied pressuremust be 20 percent higher as cited.Conversely, if the slot is not completelyfilled (as shown in Figure17), the open area will be free toradiate energy through the slot.Figure 17. Unfilled Slot is Free to Radiate WhenSpacing is Equal to 1/2 WavelengthThe cut-off frequency for polarizationsparallel to the long dimensionof the slot will be determinedby the gap height, h. The cut-offfrequency for the polarization vectorperpendicular to the slot will bedetermined by the width of the slot,w. The attenuation through the slotis determined by the approximateformulawhered = the depth of the slot,andλc is equal to 2w or 2h,depending upon thepolarization being considered.wA(dB) = 54.5 d/λcThis example also illustrates whyleakage is apt to be more for polarizationswhich are perpendicular tothe seam.For large values of βd, the percentageadjustments must be evengreater. For example, the percentageincrease required to satisfy βd= 3 is 64 percent. It is desirable,therefore, that βd should be keptas small as possible. This can beachieved by using stiff flanges orspacing bolts closer together.hGasket DesignChomerics 63

Designing a Solid-OConductive ElastomerGasket-in-a-GrooveThe “solid-O profile” is the mostoften specified conductive elastomerEMI gasket for several keyreasons. Compared to other solidcross sections, it offers the widestdeflection range to compensate forpoorly toleranced mating surfacesand to provide reliable EMI shieldingand pressure sealing. It can beinstalled in a relatively small space,and is the most easily installed andmanu factured. It also tends to beless prone to damage, due to theabsence of angles, corners or othercross section appendages.The “gasket-in-a-groove” design offersfive significant advantages oversurface-mounted EMI gaskets:1. Superior shielding, due tosubstantial metal-to-metal contactachieved when the mating surfacesare bolted together and “bottomout”. (Flat die-cut gaskets preventmetal-to-metal contact betweenmating flange members, whichreduces EMI shielding performance– especially in low frequency magneticfields.)2. Positive control over sealingperformance. Controlling the sizeof the gasket and groove can ensurethat required shielding and sealingare achieved with less carefulassembly than is required for flatgaskets. In other words, the gasketin-a-grooveis more foolproof.3. Built-in compression stopprovided by the groove eliminatesthe risk of gasket damage due toexcessive compression.4. A gasket retention mechanismcan be provided by the groove,eliminating the need for adhesivesor mounting frames.5. High current-handling characteristicsof the metal-to-metalflange design improves the EMPand lightning protection offered byan enclosure.This section presents the methodfor calculating groove and gasketdimensions which will permit theshielding system to function underworst-case tolerance conditions.Adherence to these general guidelineswill result in optimum shieldingand sealing for typical electronics“boxes”. It should be understoodthat they may not be suitable fordesigning shielding for sheet metalcabinets, doors, rooms or otherlarge, unconventional enclosures.Important Notes: The guidelinespresented here are intended toconsider only “solid O” gasketcross sections. The calculations forhollow O, solid and hollow D, andcustom gasket cross sections differfrom these guidelines in several keyareas.Chomerics generally does not recommendbonding solid O gasketsin grooves. If for some reason yourdesign requires gasket retention,contact Chomerics’ ApplicationsEngineering Department for specificrecommendations, since the useof adhesives, dove-tailed groovesor “friction-fit” techniques requirespecial design considerations notcovered here.Extreme design requirements orunusually demanding specificationsare also beyond the scopeof the guidelines presented here.Examples would include criticalspecifications for pressure sealing,exceptionally high levels of EMIshielding, excep tional resistance tocorrosion, harsh chemicals, hightemperatures, heavy vibration, orunusual mounting and assemblyconsiderations.Mechanical ConsiderationsCauses of Seal FailureIn order to produce a gasket-in-agroovesystem which will not fail,the designer must consider threemechanical causes of seal failure:gasket over-deflection and associateddamage (see Figure 18d);gasket under-deflection and loss ofseal (see Figure 18f); groove overfill,which can destroy the gasket(see Figure 18e).Designing to avoid these problemsis made more complicated by theeffects of:••worst-case tolerance conditionsdeformation of the cover (coverbowing)poor fit of mating surfaces.•The key to success involves selectionof the appropriate gasket sizeand material, and careful design ofthe corresponding groove.Deflection LimitsIn nearly every solid-O application,Chomerics recommends a minimumdeflection of 10% of gasketdiameter. This includes adjustmentsfor all worst-case tolerances of boththe gasket and groove, cover bowing,and lack of conformity betweenmating surfaces. We recommend amaximum gasket deflection of 25%of gasket diameter, considering allgasket and groove tolerances.Although sometimes modified toaccommodate application peculiarities,these limits have beenestablished to allow for stressrelaxation, aging, compression set,elastic limits, thermal expansion,etc.Maximum Groove FillSolid elastomer gaskets (as opposedto foam elastomer gaskets)seal by changing shape to conformto mating surfaces. They cannotchange volume. The recommendedlimit is 100% groove fill underworst-case tolerances of both gasketand groove. The largest gasketcross sectional area must fit intothe smallest cross sectional groovearea.Chomerics 64

Analyzing Worst-CaseTolerancesFigures 18a-c illustrate the issuesof concern, and identify the parameterswhich should be consideredin developing an effective design.Figures 18d and e illustrate twodifferent cases which can resultin gasket damage in the area oftorqued bolts. In Figure 18d, therelationship between groove depthand gasket diameter is critical inavoiding over-deflection. In Figure18e, sufficient groove volume mustbe provided for a given gasket volumeto permit the gasket to deflectwithout over-filling the groove.As shown in Figure 18f, cover deformationand groove sizing must becontrolled to make sure the gasketis sufficiently deflected to seal thesystem.Since a single gasket and grooveare employed for the entire perimeter,the design must be optimizedfor each of the worst-case examplesillustrated in Figures 18d-f.SolidO-profileEMI gasketGroovefor gasketFlangeFigure 18a. Exploded View of Electronic EnclosureView forsection A-ACoverEnclosureCoverBolt Spacing (L)View forsection A-ALack ofconformity(LOC)Gasket DesignFlange“O” Stripconductive elastomerin rectangular grooveFlange width (FW)Figure 18b. Cut-away View of AssemblyBolt outboardof grooveBolt spacing (L)Cover thickness (T)CBCover bowing (CB)BConductive elastomergasket in grooveCFigure 18c. Section A-A of Assembled Enclosure Flange and Gasket(Sectioned midway through gasket and groove)Chomerics 65

Figure 18d Section B-B from Figure 18c –Worst Case Maximum Deflection (Maximumgasket diameter, minimum groove depth)Gasket damageMaximumdiameter gasketBoltOptional washerProblem: Gasket too tall for minimum groovedepth (deflection beyond elastic limit).Results in gasket damage or fracture.Gasket deflectedmore than 25%MinimumgroovedepthNominalgroove depthSolution: Over-deflection avoided with smallermaximum gasket diameter and/or deeperminimum groove depth.Gasket deflected25% or lessMinimumgroovedepthNominalgroove depthFigure 18e Section B-B from Figure 18c –Worst Case Maximum Groove Fill (Maximumgasket diameter in minimum groove depth andwidth)Problem: Minimum groove dimension cannotaccommodate maximum gasket diameter,resulting in gasket damage.MinimumgroovewidthNominalgroovewidthMaximumdiameter gasketMinimumgroovedepthGasket damageNominalgroove depthSolution: Groove over-fill avoided with smallermaximum gasket diameter and/or greaterminimum groove depth and/or width.NominalgroovewidthNominalgroove depthFigure 18f Section C-C from Figure 18c – WorstCase Minimum Deflection (Minimum gasketdiameter in maximum depth groove, aggravatedby cover bowing and lack of conformity betweenmating surfaces)Minimum diameter gasketProblem: Gasket will not be deflected therecommended 10% minimum. Combinedeffects of tolerances, cover bowing, and lackof conformity can result in complete lossof cover-to-gasket contact over time, andconsequent seal failure.Gasketdeflectedless than 10%Maximumgroove depthNominalgroove depthSolution: Under-deflection avoided with largerminimum gasket diameter and/or shallowermaximum groove depth.Gasketdeflected10% or moreNominalgroove depthMaximumgroove depthChomerics 66

Calculating the Dimensions andTolerances for the Groove andEMI GasketFigure 19 diagrams the calculationand decision sequence requiredto determine the dimensions fora groove system. Because therelationship between groove depthand gasket diameter is central toseal performance, groove depthis selected as the key variable todetermine first.Start by making an educated guessas to reasonable values for grooveand gasket sizes and tolerances,based on desired nominal gasketdeflection of 18%. For example,if 0.025 in. of gasket deflectionis desired, start with a nominalgasket diameter of 0.139 in. This iscalculated by dividing the desiredtotal gasket deflection by 0.18 toestimate the required gasket size.(Total Gasket Deflection ÷ 0.18 =Approx. Nominal Gasket Size.) Thisrelationship is an alternate formof Formula 1. Final groove dimensionscan only be determined aftercompleting all of the calculationscalled for in Figure 19, and arrivingat values which remain withinthe recommended limits for gasketdeflection and groove fill.Figure 19. Procedure for Calculating Gasket and Groove DimensionsSELECT A REASONABLE GASKET DIAMETERCALCULATE NOMINAL GROOVE DEPTH (Formula 1)ESTABLISH TOLERANCESCALCULATE MAXIMUM GASKET DEFLECTION (Formula 2)Adjust parameters if this value is more than 25%CALCULATE MINIMUM GASKET DEFLECTION (Formula 3)Adjust parameters if this value is less than 10%Gasket DesignCALCULATE NOMINAL GROOVE WIDTH (Formula 4)VERIFY THAT FINAL GROOVE DIMENSIONS SATISFY BOTH MIN.AND MAX. GASKET DEFLECTION AND GROOVE FILL LIMITSUNDER WORST-CASE TOLERANCE CONDITIONSChomerics 67

Formulas (see definition of terms at right)1. Nominal Groove Depth2. Maximum Gasket Deflection(Worst Case, expressed as a % of gasket diameter)(GaD nom + GaT) – (GrDGaDf max = 100[ nom(GaD nom]– GrDT)+ GaT)whereb.(Note: Formula must be adjusted when using metric units)andGrD nom = 0.82 GaD nom3. Minimum Gasket Deflection(Worst Case, expressed as a % of gasket diameter)(GaDa.nom + GaT) – (GrD nom +GrDT) – CB – LOCGaDf min = 10[ (GaD nom –]GaT)4GDF x L maxCB min =FW X T 3 X E X 32minc. LOC = 0.001 in. for machined surfaces with surfaceroughness of 32-64 μin. RMS.(For discussion, see Terms.)4. Nominal Groove Widtha. GaA max= 0.7854* (GaD nom+ GaT) 2b. GrW min= GaA maxGrD minc. GrW nom= GrW min+ GrWT*Note: 0.7854 =π4TermsAll values may be calculated in inches or mmunless otherwise indicated.GaA max– Maximum gasket cross section area(in 2 or mm 2 )GaD nom– Nominal gasket diameterGaT – Gasket tolerance (difference betweenmax. and nom. or min. and nom.)GrW min– Minimum groove widthGrWT – Groove width toleranceGrW nom– Nominal groove widthGrD min– Minimum groove depthGrD nom– Nominal groove depthGrDT – Groove depth tolerance (differencebetween max. and nom. or min. and nom.)GaDf max– Maximum gasket deflection (%)GaDf min– Minimum gasket deflection (%)L max– Maximum bolt spacingFW min– Minimum flange widthT min– Minimum cover thicknessGDF – Gasket deflection force (ppi or Newtonsper meter).Note: For the purpose of this guide, the GDFvalue should represent the worst-case minimumgasket deflection arising from cover bowing. Forexample, the GDF is taken at 10% deflection forthe calculation in Formula 3b.E – Young’s modulus. (For alumi num, use1 x 10 7 psi, or 7 x 10 5 kg/cm 2 .)CB – Cover bowing, generally calculatedby modeling the elastic deformation of thecover as a uniformly loaded beam with twofixed supports. (The moment of inertia of thecover is modeled as a rectangular beam, the“height” of which is taken to be equal to thecover thickness, while “width” is consideredequal to flange width. The moment of inertiacan be adjusted for cover configu rations otherthan flat. Refer to an engineering handbookfor the necessary revisions to Formula 3b.)An assumption is made that one side of acover/flange interface is infinitely stiff, typicallythe flange. If this is not essen tially true, elasticdeformation of each is computed as though theother were infinitely stiff, and the two valuescombined.LOC – Lack of conformity, the measure ofthe mismatch between two mating surfaceswhen bolted together, expressed in inches.Experience has shown that machined surfaceswith a surface roughness of 32-64 μin. RMSexhibit an LOC of 0.001 in. It is left to theengineer’s judgment to determine LOC for othersurfaces. LOC can be determined empiricallyfrom measurements made of actual hardware.In this guide, LOC applies only to the surfaceswhich form the EMI shielding interface.Chomerics 68

CHOMERICS DIVISION OF PARKER HANNIFIN CORPORATIONTERMS AND CONDITIONS OF SALE (7/21/04)1. Terms and Conditions of Sale: Alldescriptions, quotations, proposals,offers, acknowledgments, acceptancesand sales of Seller’s productsare subject to and shall be governedexclusively by the terms and conditionsstated herein. Seller’s prices for theproducts have been established on theunderstanding and condition that theterms set forth herein shall apply to thissale to the exclusion of any other terms.Seller expressly reserves the right to anequitable adjustment to the price in theevent that any material provision hereofis deemed not to govern the rightsand obligations of the parties hereto.Buyer’s acceptance of any offer to sellis limited to these terms and conditions.Any terms or conditions in addition to,or inconsistent with those stated herein,proposed by Buyer in any acceptance ofan offer by Seller, are hereby objectedto. No such additional, different orinconsistent terms and conditions shallbecome part of the contract betweenBuyer and Seller unless expresslyaccepted in writing by Seller. Seller’sacceptance of any offer to purchaseby Buyer is expressly conditional uponBuyer’s assent to all the terms andconditions stated herein, including anyterms in addition to, or inconsistentwith those contained in Buyer’s offer.Acceptance of Seller’s products shall inall events constitute such assent.2. Product Selection. If Seller hasprovided Buyer with any componentand/or system recommendations, suchrecommendations are based on dataand specifications supplied to Seller byBuyer. Final acceptance and approvalof the individual components as wellas the system must be made by theBuyer after testing their performanceand endurance in the entire applicationunder all conditions which might beencountered.3. 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Changes, Reschedules and Cancellations:Buyer may request to modifythe designs or specifications for theitems sold hereunder as well as thequantities and delivery dates thereof,or may request to cancel all or part ofthis order; however, no such requestedmodification or cancellation shallbecome part of the contract betweenBuyer and Seller unless accepted bySeller in a written amendment to thisAgreement. Acceptance of any suchrequested modification or cancellationshall be at Seller’s discretion, and shallbe upon such terms and conditions asSeller may require.9. Special Tooling: A tooling charge maybe imposed for any special tooling, includingwithout limitation, dies, fixtures,molds and patterns, acquired to manufactureitems sold pursuant to this contract.Such special tooling shall be andremain Seller’s property notwithstandingpayment of any charges by Buyer. Inno event will Buyer acquire any interestin apparatus belonging to Sellerthat is utilized in the manufacture ofthe items sold hereunder, even if suchapparatus has been specially convertedor adapted for such manufacture andnotwithstanding any charges paid byBuyer. Unless otherwise agreed, Sellershall have the right to alter, discard orotherwise dispose of any special toolingor other property in its sole discretion atany time.10. Buyer’s Property: Any designs, tools,patterns, materials, drawings, confidentialinformation or equipment furnishedby Buyer or any other items whichbecome Buyer’s property, may be consideredobsolete and may be destroyedby Seller after two (2) consecutive yearshave elapsed without Buyer placing anorder for the items which are manufacturedusing such property. Sellershall not be responsible for any loss ordamage to such property while it is inSeller’s possession or control.11. 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Seller will defend atits expense and will pay the cost of anysettlement or damages awarded in anaction brought against Buyer based onan allegation that an item sold pursuantto this contract infringes the IntellectualProperty Rights of a third party. Seller’sobligation to defend and indemnifyBuyer is contingent on Buyer notifyingSeller within ten (10) days after Buyerbecomes aware of such allegations ofinfringement, and Seller having solecontrol over the defense of any allegationsor actions including all negotiationsfor settlement or compromise. Ifan item sold hereunder is subject to aclaim that it infringes the IntellectualProperty Rights of a third party, Sellermay, at its sole expense and option,procure for Buyer the right to continueusing said item, replace or modify saiditem so as to make it noninfringing,or offer to accept return of said itemand return the purchase price less areasonable allowance for depreciation.Notwithstanding the foregoing,Seller shall have no liability for claimsof infringement based on informationprovided by Buyer, or directed to itemsdelivered hereunder for which thedesigns are specified in whole or part byBuyer, or infringements resulting fromthe modification, combination or use ina system of any item sold hereunder.The foregoing provisions of this Part12 shall constitute Seller’s sole andexclusive liability and Buyer’s sole andexclusive remedy for infringement ofIntellectual Property Rights. If a claim isbased on information provided by Buyeror if the design for an item deliveredhereunder is specified in whole or inpart by Buyer, Buyer shall defend andindemnify Seller for all costs, expensesor judgments resulting from any claimthat such item infringes any patent,trademark, copyright, trade secret orany similar right.13. Export Limitations. The items soldhereunder are authorized by the U.S.government for export only to the countryof ultimate destination indicated onthe face hereof for use by the end-user.The items may not be transferred,transshipped on a non-continuous voyage,or otherwise be disposed of in anyother country, either in their originalform or after being incorporated intoother end-items, without the prior writtenapproval of the U.S. government.14. Commercial Items. Unless otherwiseindicated on the face hereof, theitems being sold hereunder if sold formilitary or government purposes constituteCommercial Items in accordancewith FAR 2.101, and as such the assertionsdelineated in the DFAR’s 252.227-7013, 252.227-7014, 252.227-7017 andFAR 52.227-15 (c) shall not apply to thiscontract. Additionally, in view of theCommercial Item status, any deliverabletechnical data and/or computersoftware to be provided will containSeller’s normal commercial legendsubject to the restrictions containedtherein.15. Force Majeure: Seller does notassume the risk of and shall not beliable for delay or failure to performany of Seller’s obligations by reason ofcircumstances beyond the reasonablecontrol of Seller (hereinafter ‘Eventsof Force Majeure’). Events of ForceMajeure shall include without limitation,accidents, acts of God, strikes or labordisputes, acts, laws, rules or regulationsof any government or governmentagency, fires, floods, delays or failuresin delivery of carriers or suppliers,shortages of materials and any othercause beyond Seller’s control.16. Premier Conductive Plastics:Parker Chomerics Premier conductiveplastics are sold under licensesolely for use in the following applications:(i) EMI/RFI shielding, i.e.,electromagnetic and/or radio frequencyinterference shielding or compatibilityand surface grounding therefore;(ii) earth grounding, corona shielding,and anti-static and/or electrostaticdischarge protection shielding; and (iii)as thermally conductive members todissipate heat generated by electronicdevices.The resale of Premier conductiveplastics in pellet or any other raw materialform is expressly prohibited, as istheir use in any application other thanas stated above, and any such resaleor use by you or your customers shallrender any and all warranties null andvoid ab initio.You shall defend, indemnify, and holdParker Hannifin Corporation and itssubsidiaries (Parker) harmless fromand against any and all costs andexpenses, including attorney’s fees,settlements, and any awards, damages,including attorney’s fees, and costs, resultingfrom any claim, allegation, suitor proceeding made or brought againstParker arising from any prohibited useof Premier conductive plastics by youor your customers.17. Entire Agreement/Governing Law:The terms and conditions set forthherein, together with any amendments,modifications and any different termsor conditions expressly accepted bySeller in writing, shall constitute theentire Agreement concerning the itemssold, and there are no oral or otherrepresentations or agreements whichpertain thereto. This Agreement shallbe governed in all respects by the law ofthe State of Ohio. No actions arising outof the sale of the items sold hereunderor this Agreement may be brought byeither party more than two (2) yearsafter the cause of action accrues.Chomerics 70

Parker Hannifin plcConditions of Sale(Practice Note: These terms are notsuitable for use in other countries unlessParker Hannifin Plc is the Seller)(as of March, 08 2005)Goods sold under these conditions aresubject to retention of title - Condition101. DEFINITIONSIn these Conditions:“the Company” means Parker Hannifinplc including all divisions andbusinesses thereof and any subsidiaryundertaking thereof (as defined in Sections258 and 259 Companies Act 1985as amended);“Conditions” means the Standard Conditionsof Sale set out in this documenttogether with any special terms agreedin writing between the Company and theBuyer;“Contract” means any contract betweenthe Company and the Buyer for the saleand purchase of the Goods formed inaccordance with Condition 2;“the Buyer” means any company, firmor individual or agent thereof to whomthe Company’s quotation or acknowledgementof order is addressed;“the Goods” means the products(including any parts or accessories),materials and/or services to be suppliedby the Company.2. APPLICABILITY OF CONDITIONSThe Company concludes Contractsfor the supply of Goods subject only tothese Conditions. The Buyer acceptsthat these Conditions shall governrelations between himself and theCompany to the exclusion of any otherterms and conditions including, withoutlimitation, conditions and warrantieswritten or oral express or implied evenif contained in any of the Buyer’s documentswhich purport to provide that theBuyer’s own terms and conditions shallprevail. No variation or qualification ofthese Conditions or of any quotationor Contract arising herefrom shall bevalid unless agreed in writing by theSecretary or a Director of the Companyor other person duly authorised by theBoard of Directors of the Company.3. QUOTATIONSThe Company’s quotations are givenwithout commitment and no Contractbetween the Company and the Buyershall arise unless and until the Companyhas accepted in writing the Buyer’sorder placed on the Company’s quotation.Quotations shall be valid for aperiod of 30 days from the date of issue,or (if different) the period specified withthe quotation itself.4. REPRESENTATIONSNo employee of the Company otherthan the Secretary or a Director of theCompany is authorised to make anystatement or representations as to theGoods, save that this restriction shallnot apply to any notice or statementcontaining a warning or restriction ofuse (“Warnings”) which may be providedin connection with the Goods. Subjectto such Warnings, the Buyer, therefore,shall not be entitled to rely or to seek torely upon any statement or representationmade by an employee or agent ofthe Company other than the Secretaryor a Director.5. PRICES(i). Subject to Condition 3, prices containedin a quotation price list catalogueand similar matter shall be based uponcurrent costs ruling at the date thereofand are for guidance only. Subject to thelater provisions of this Condition 5 thecontract price shall be the price currentat the date of delivery of the goodsand/or when services are performed asthe case may be.(ii). Where firm prices are agreed (includingwithout limitation any quotationwhere the price is fixed pursuant toCondition 3) the prices will remain firmprovided that full information permittingmanufacture to proceed is received bythe Company promptly after acknowledgementof the order by the Company,and further provided the Buyer takesdelivery of the order when ready. Ifdelivery of the order or any part thereofis delayed at the ‘Buyer’s request orthrough the Buyer’s failure to providethe full information mentioned above,the Company reserves the right toamend the price of the undelivered portionto the Company’s price list prevailingat the date when delivery is made.(iii). Where a quotation is given dependenton information supplied by theBuyer, the Buyer will be responsiblefor the accuracy of the informationgiven, and for the supply of all relevantparticulars. Any increased cost incurredeither during or after manufacture resultingfrom any inaccuracy or omissionshall be borne by the Buyer alone andshall be paid promptly, and independentlyof the main contract price.(iv). Unless otherwise stated prices donot include VAT which will be chargeableat the date of despatch and/orperformance of services as the casemay be.6. DESPATCH AND DELIVERY(i). Delivery shall be deemed to occurand the risk of loss or damage ofany kind in the Goods shall pass to theBuyer on whichever of the followingevents occur earlier.(a) collection by or on behalf of theBuyer or by a carrier for despatch to theBuyer (whether or not such carrier bethe Company’s agent or servant)(b) 14 days from the date of notice givenby the Company that the Goods areready for collection or despatch.(ii). In the event that the Company shallat the specific request of the Buyerstore the Goods or arrange for theGoods to be despatched or dealt withotherwise than by collection by theBuyer then the Buyer shall pay to theCompany any reasonable charges madein the Company’s absolute discretion forthe provision or procurement of suchservices. Any such services providedby the Company shall be performedsubject to these Conditions. In the eventthat such services are to be providedby a carrier or other third party thenthe Company shall in arranging for theprovision of the same act only as theagent of the Buyer and the Buyer shallindemnify the Company against anycost, charge liability or expense (includingdemurrage) thereby incurred by theCompany.Chomerics 71

(iii). The Buyer shall carefully examinethe Goods on receipt of the same andshall by written notice to be received bythe Company within 21 days of receiptof the Goods notify the Company ofany short delivery, over delivery or anydefects reasonably discoverable oncareful examination. In the absence ofreceipt of such notice, then subject onlyto Condition 11, the Company shall bedischarged from all liability in respect ofsuch defects or short or over delivery.(iv). If the Buyer neglects to serve noticeunder sub Condition (iii) above of anyover delivery then the Company may atits option either repossess the excessGoods or invoice them and be paidforthwith by the Buyer for the excessGoods at the price ruling at the date ofdelivery.7. TIME FOR AND FORM OF DELIVERY(i). The Company will use reasonablecommercial endeavours to deliver theGoods and to perform services in accordancewith any time stated in thecontract but time of delivery or performanceshall not be of the essence tothe contract. Any such times are statedby way of general information only andin the event of failure to despatch ordeliver or perform within such times forany cause (whether within or) outsidethe Company’s reasonable control, thesame shall not be a breach or repudiationof the contract nor shall theCompany have any liability to the Buyerfor any direct, indirect or consequentialloss (all three of which terms includewithout limitation pure economic loss,loss of profits, loss of business, depletionof goodwill and like loss) howevercaused (including as a result of negligence)by delay or failure in deliveryexcept as set out in this Condition 7(i).Any delay or failure in delivery will notentitle the Buyer to cancel the orderunless and until the Buyer has given60 days’ written notice to the Companyrequiring delivery to be made and theCompany has not fulfilled deliverywithin that time. If the Buyer then cancelsthe order:(a) the Company will refund the Buyerany sums the Buyer has paid to theCompany in respect of that cancelledorder; and(b) the Buyer will be under no liability tomake any payments in respect of thatcancelled order.(ii). (a) If the Contract does not otherwiseprovide the Company shall be entitledto deliver Goods by single deliveryor by instalments at its option.(b) If the Contract provides for deliveryby instalments or the Company soelects each instalment shall be deemedto be the subject of a separate contracton these conditions and withoutprejudice to sub-paragraph (i) hereofnon-delivery or delay in delivery shallnot affect the balance of the contractnor entitle the Buyer to terminate thesame.(iii). In the event that the Goods shallnot have been collected by or on behalfof the Buyer or by a carrier for despatchto the Buyer within 14 days of theCompany’s written notice pursuant toCondition 6 (i) (b) hereof then the Companymay at any time thereafter sendto the Buyer a further notice notifyingthe Buyer of the Company’s intention tosell the same after the expiration of aperiod of not less than 7 days from thedate of the notice and any such sale bythe Company may be on a forced salebasis. The Buyer shall be liable forthe Company’s charges and expensesfor the sale and for the storage of theGoods (which shall be at the risk of theBuyer) pending their sale hereunderor delivery to the Buyer. The Companyshall charge all costs incurred on aweekly basis for storage.8. PERFORMANCE PREVENTED ORHINDEREDThe Company shall not be liable forany delay of failure in carrying out itsobligations which is caused wholly orpartly by reason of act of God, delay intransportation, labour disputes, fire,flood, war, accident, Government action,inability to obtain adequate labour,materials, manufacturing facilitiesor energy, or any other cause beyondthe Company’s control or that of itsservants or agents, and if the delay orfailure has continued for a period of3 months then either party may givenotice in writing to the other determiningthe contract and on such terminationthe Company shall refund to theBuyer the price of the Goods or any partthereof already paid to the Company afterdeduction of any amount due to theCompany including any amount underCondition 17 hereof.9. PAYMENT(i). Unless expressly agreed in writingpayment shall be made in sterling incleared funds without any deductionset-off, restriction condition or defermenton account of any disputes orcross claims or present or future taxes,levies, duties or charges whatsoever(unless and to the extent the Buyer isrequired by law to make such deduction)on or before the last day of themonth following the month of the invoicefor the Goods. Where full paymentis not received by the due date interestshall accrue on the sum outstandingat the rate of 3% per annum above thebase rate of Lloyds Bank plc (as variedfrom time to time) calculated on adaily basis but without prejudice to theCompany’s rights to receive paymentson the due dates.(ii). Time for payment shall be of theessence and in the event of delay ordefault in any payment for more than7 days, the Company shall be entitledto suspend deliveries of Goods (beingthose Goods the subject of the defaultand any other Goods the subject of anyagreed order) and/or treat the Contract(and any other Contract between theCompany and the Buyer) as repudiatedand/or re sell any of the Goods in itspossession and be indemnified by theBuyer for any loss thereby incurred.(iii). All sums payable to the Companyunder the Contract will become dueimmediately on termination of theContract.(iv). The Buyer shall pay for any samples,sale or return, loan or demonstrationgoods and/or materials, includingdrawings, plans, specifications etc. notreturned within one month from thedate of receipt by the Buyer unless adifferent period for the return of suchgoods and/or materials is agreed betweenthe Company and the Buyer.10. PROPERTY IN GOODS(i) The Company shall retain absoluteownership of the property in the Goodswhich shall not pass to the Buyer andthe Buyer shall keep and retain theGoods as bailee for and on behalf ofthe Company and shall deliver up theGoods to the Company at the Company’srequest until the Company has receivedfull payment of the price of the Goodsand full payment of any other sumswhatsoever which are outstanding fromthe Buyer to the Company whether ornot due and owing, and until such timethe Buyer:(a) shall insure the Goods against theusual risks with an insurance office ofrepute;(b) shall store separately the Goodsor in some other way ensure that theGoods are readily identifiable as theChomerics 72

property of the Company;(c) irrevocably authorises the representativesof the Company at any timein circumstances where the provisionsof Condition 19 may apply to enter theBuyer’s premises where the Goods areor are thought by the Company to bestored for the purpose of repossessingthe Goods;(d) shall keep and retain the Goods freefrom any charge lien or other encumbrancethereon.(ii). Provided always that no circumstanceshave arisen where the provisionsof Condition 17 may apply theBuyer shall be entitled to offer forsale and sell the Goods in the ordinarycourse of business as principal and notas agent at the best obtainable price,and shall be a sale of the Company’sproperty on the Buyer’s own behalfand the Buyer will deal as principal inrespect of such sale. Notwithstandingthe other provisions of the Contract,payment shall become due (unless paymenthas already become due or beenpaid) when the Buyer receives paymentupon its own sale of the Goods (or otheritems incorporating the Goods).(iii). If the Buyer incorporates any Goodswithin other equipment or productsprovided that the Goods remain readilyidentifiable and a removable part ofsuch other equipment or products theprovisions of Condition 10(i) shall apply.(iv). If the provisions of Condition 10(iii)apply the Buyer shall store separatelythe other equipment or products incorporatingthe Goods and shall notifythe Company of the precise locationand position thereof. The provisions ofCondition 10(ii) hereof shall apply mutatismutandis in respect of the Goodscontained within such other equipmentor products owned by the Company.(v). The Company shall be entitled toexercise a general lien or right of retentionon all goods or any parts thereofin the Company’s possession whichare the Buyer’s property for any sumswhatsoever due to the Company andpursuant to such lien or right the Companyshall be entitled without notice tothe Buyer to sell all or any part of suchGoods or part thereof privately or byauction or otherwise and to keep theproceeds of sale in diminution of suchsums and of all costs and expensesincurred by the Company in effectingthe said sales.11. WARRANTY AND LIMITATIONOF LIABILITY(i). The Company warrants that products,parts or materials manufacturedby it will be of good materials and workmanshipand that reasonable care willbe employed in assembling or incorporatingitems not manufactured by it andin performing services so that upon theBuyer giving written notice to the Companythat Goods have not been suppliedor services performed as aforesaid ifthe same be established the Companywill at its own expense at its optionreplace or repair such defective goodsor remedy such defaults in service.The warranty obligation shall not applywhere the Goods have been tamperedwith, improperly altered, repaired ormaintained, installed or connected orsubject to misuse (in each case otherthan as a result of the Company’s ownacts or omissions). The Buyer shall atits own cost return the Goods to theCompany for inspection.(ii). The same term shall apply mutatismutandis in respect of such replacement,repair or remedial services.(iii). The above warranty shall apply inrespect of matters whereof the Buyergives written notice within 12 monthsof delivery or 6 months from installation(whichever is the shorter period)or within 12 months of performance orof replacement repair or remedial servicesrespectively after which any claimin respect thereof shall be absolutelybarred (subject to the other provisionsof this Condition 11).(iv) . The Company does not exclude itsliability (if any) to the Buyer:(a) for breach of the Company’s obligationsarising under Section 12 Sale ofGoods Act 1979 or Section 2 Supply ofGoods and Services Act 1982;(b) for personal injury or death resultingfrom the Company’s negligence;(c) under section 2(3) Consumer ProtectionAct 1987;(d) for any matter which it would beillegal for the Company to exclude or toattempt to exclude its liability; or(e) for fraud.(v). Except as provided in Conditions 7(i)and 11(i) to (iv), the Company will beunder no liability to the Buyer whatsoever(whether in contract, tort (includingnegligence), breach of statutoryduty, restitution or otherwise) for anyinjury, death, damage or direct, indirector consequential loss (all three of whichterms include, without limitation, pureeconomic loss, loss of profits, loss ofbusiness, depletion of goodwill and likeloss) howsoever caused arising out of orin connection with:(a) any of the Goods, or the manufactureor sale or supply, or failure or delay insupply, of the Goods or performanceor failure or delay in performance ofservices by the Company or on the partof the Company’s employees, agents orsub-contractors;(b) any breach by the Company of anyof the express or implied terms of theContract;(c) any use made or resale by the Buyerof any of the Goods, or of any productincorporating any of the Goods;(d) any statement made or not made,or advice given or not given, by or onbehalf of the Company.(vi). Except as set out in Conditions 7(i)and 11(i) to (iv), the Company excludesto the fullest extent permissible by lawall conditions, warranties and stipulations,express (other than those set outin the Contract) or implied, statutory,customary or otherwise which, but forsuch exclusion, would or might subsistin favour of the Buyer.(vii) Each of the Company’s employees,agents and subcontractors may relyupon and enforce the exclusions andrestrictions of liability in Conditions 7(i)and 11(iv) to (vi) in that person’s ownname and for that person’s own benefitas if the words “its employees, agentsand subcontractors” followed “Company”where it appears in those Conditions(save for Condition 11(v)(a)).(viii). Without prejudice to the foregoingif called upon so to do by the Buyer inwriting the Company shall use its bestendeavours to assign to the Buyer thebenefits of any warranty, guarantee, indemnity,claim, privilege or other rightswhich the Company may have in regardto manufacturers or suppliers of anygoods not manufactured by the Companyin relation to the quality, conditionor description of such goods.12. OPERATING INSTRUCTIONS(i) The Company supplies with theGoods adequate information as to theirdesign and conditions of the instructionsfor operation for compliance withits obligations under Section 6 (1) (c) ofthe Health and Safety at Work Act 1974.(ii) The Buyer undertakes that all neces-Chomerics 73

sary steps will be taken to ensure thatthe Goods will be safe and without riskto health when properly used in accordancewith Section 6 (8) of the Healthand Safety at Work etc. Act 1974.13. DRAWINGS, SPECIFICATIONSETC.(i) All descriptions, drawings, illustrations,particulars of weights andmeasures rating standard statementsor details or specifications or otherdescriptive matter, whether or notcontained in the contract document, areapproximate only. The Goods will be inaccordance with the Company’s specificationsat the time of manufactureand any earlier specifications drawings,descriptions, illustrations, particularsas to weights and measures ratingstandard statements or details shall notform part of the description of the partsor services supplied or to be suppliedso that the Company shall not be underany liability in respect thereof.(ii) Where Goods are supplied by theCompany to the Buyer in accordancewith the Buyer’s design or specificationor where the Company shall designitems not within the standard range ofproducts at the Buyer’s request no warrantyis given or implied as to the suitabilityof such goods or items unless theBuyer has made the Company awareof the particular purpose for which theBuyer is proposing to use the goods oritems in which case Condition 11 shallapply. The Company shall be entitled tocharge a fee for any research or designundertaken in connection with the supplyof Goods not within their standardrange of products.14. INSPECTION AND TESTINGThe Company undertakes inspection ofall Goods prior to delivery and wherepracticable submits to standard tests atthe Company’s premises Special testsor standard tests in the presence of theBuyer or his representative may be undertakenby the Company at the requestand expense of the Buyer but unlessotherwise agreed such tests shall beconducted at the Company’s premises.15. INDUSTRIAL PROPERTYRIGHTS(i) All intellectual property rights subsistingin or relating to any calculations,data, specifications, designs, drawings,papers, documents, procedures,techniques, acceptance, maintenanceand other tests special and recommendedparts and other equipmentand any other material and informationwhatsoever given to the Buyer by theCompany in connection with the supplyof the Goods by the Company to theBuyer or otherwise are vested in theCompany. The Buyer will not whether byitself its officers servants agents or anyof them or otherwise howsoever copy orreproduce any such items or material inwhole or in part nor will it disclose anysuch information in whole or in part toany third party. Further the Companyshall be entitled to the ownership of allintellectual property rights subsistingin or relating to any calculations, data,specifications, designs, drawings, papers,documents or other items materialor information conceived originateddeveloped or produced by the Companyfor the Buyer pursuant to the contractfor the supply of Goods.(ii) The Buyer shall not at any time forany reason whatsoever disclose orpermit to be disclosed to any person orpersons whatsoever or otherwise makeuse of or permit to be made use ofany trade secrets or other confidentialinformation relating to the equipmenttechnology business affairs or financesof the Company or any associated Companyor organisation of the Companyor relating to the Company’s agentsdistributors licensees or other customersor in respect of any of their dealingsor transactions.(iii) The Buyer shall not seek to applyor apply to register in its own name anyof the Company’s intellectual propertyrights and in particular those subsistingin or relating to the Goods or a partthereof nor shall it represent in any waythat it has any right or title to the ownershipof any such intellectual propertyrights nor shall it do any act or thingwhich might be contrary to the interestor rights of the Company in such rightsand in particular challenge the ownershipor validity of such rights.(iv) The Buyer at its own expense shalldo all such acts and things and shallsign and execute all such deeds anddocuments as the Company in its solediscretion may require in connectionwith any steps or proceedings taken bythe Company to restrain the infringementof it intellectual property rights.(v) The Buyer undertakes and agreesthat the use of any of its calculations,data, specifications, designs, drawings,papers, documents, procedures,techniques, acceptance, maintenanceand other tests special and recommendedparts and other equipment andother material and information by thecompany when manufacturing and supplyingthe Goods will not infringe anyintellectual property rights of a thirdparty and shall indemnify the Companyin respect of any such infringement.(vi) The Buyer shall not alter or removeany trade mark of the Company whichhas been applied to the Goods nor applyany other trade mark to the Goods normake any alteration to their packagingand get up.(vii) The provisions of this Condition 15shall survive the expiry or terminationof any Contract for whatever reason.16. SUB CONTRACTINGThe Company shall be entitled to subcontract all or any of its obligationshereunder.17. DETERMINATIONIf the Buyer shall make default in orcommit a breach of the contract or ofany of his obligations to the Companyor if any distress or execution shallbe levied upon the Buyer’s propertyor assets, or if the Buyer shall makeor offer to make any arrangement orcomposition with creditors or commitany act of bankruptcy, or if any petitionor receiving order in bankruptcy shallbe presented or made against him, orif the Buyer is a limited company andany resolution or petition to wind upsuch company’s business (other thanfor the purpose of a solvent amalgamationor reconstruction) shall bepassed or presented, or if a receiverof such company’s undertaking propertyor assets or any part thereof shallbe appointed the Company shall havethe right forthwith to determine anyContract then subsisting and uponwritten notice of such determinationbeing given to the Buyer any subsistingContracts shall be deemed to have beendetermined and the Company shall beentitled to recover from the Buyer alllosses thereby arising including but notlimited to those under Condition 18 ofthese Conditions or otherwise.18. PARTIAL COMPLETIONIn the case of partial completion of anorder by reason of any of the eventsreferred to in Conditions 8 or 17 theCompany shall be entitled to a quantummeruit in respect of all work done byit including labour costs and materialsand any charges or expenses which theCompany is committed to pay sub con-Chomerics 74

tractors or third parties without prejudiceto its rights should non completionbe occasioned by the Buyer.19. NOTICESUnless otherwise provided in writingany written communication or noticeunder the Contract shall be made orgiven by sending the same by ordinaryprepaid first class letter post in the caseof the Company to its current addressand in the case of the Buyer to its lastknown address and if so sent shall bedeemed to be made or given two daysafter the date when posted.20. WAIVERAny failure by the Company to enforceany or all these Conditions shall notbe construed as a waiver of any of theCompany’s rights.21. CONTRACTS (RIGHTS OF THIRDPARTIES) ACTThe parties to the Contract do notintend that any of its terms will beenforceable by virtue of the Contracts(Rights of Third Parties) Act 1999 by anyperson not a party to it.22. LAW AND INTERPRETATIONThe Contract shall be governed byEnglish law and the Buyer shall submitto the non exclusive jurisdiction of theEnglish Courts. If any of these Conditionsor any part thereof is renderedvoid or unenforceable by any legislationto which it is subject or by any rule oflaw it shall be void or unenforceable tothat extent and no further.Chomerics 75

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Chomerics Capabilities Include:EMI SHIELDING & COMPLIANCE••••••••••••Conductive elastomers – molded, extruded, and form-in-place (FIP)Conductive foam based gaskets – fabric-over-foam and z-axis foamConductive compounds – adhesive, sealants and caulksRF and thermal/RF absorbing materialsEMI shielding plastics and injection molding servicesCoatings – direct metallization and conductive paintsMetal gaskets – Springfingers, metal mesh and combination gasketsFoil laminates and conductive tapesEMI shielding vents – commercial and military honeycomb ventsShielded optical windowsCable shielding – ferrites and heat-shrink tubing/wire mesh tape/zippered cable shieldingCompliance and safety test servicesTHERMAL MANAGEMENT & CONTROL••••••••••Thermally conductive gap filler padsDispensed thermal gap fillersSilicone-free thermal padsPhase-change materials (PCM)Polymer solder hybrids (PSH)Dispensable thermal compoundsThermal grease and gelsInsulator padsThin flexible heat spreadersCustom integrated thermal/EMI assembliesAbout Parker Hannifin CorporationParker Hannifin is the world’s leading diversified manufacturer of motion and control technologiesand systems, providing precision-engineered solutions for a wide variety of commercial, mobile,industrial and aerospace markets. For more information, visit http://www.parker.com.Chomerics

Chomerics WorldwideNorth AmericaDivision HeadquartersWoburn, MAphone +1 781-935-4850fax +1 781-933-4318chomailbox@parker.comCranford, NJphone +1 908-272-5500fax +1 908-272-2741Millville, NJphone +1 856-825-8900Fax +1 856-825-8969Fairport, NYphone +1 585-425-7000Fax +1 585-425-7238South AmericaSao Paulo, Brazilphone +55 11 3917 8544fax +55 11 3917 8563EuropeMarlow, UKphone +44 1628 404000fax +44 1628 404091chomerics_europe@parker.comGrantham, UKphone +44 1476 590600fax +44 1476 591600Saint Ouen L’Aumone (Paris),Francephone +33 1 34 32 39 00fax +33 1 34 32 58 00Asia PacificHong Kongphone +852 2428 8008fax +852 2786 3446chomerics_ap@parker.comBeijingphone +86 10 6788 4650fax +86 10 6788 4649Shanghaiphone +8621 2899 5000fax +8621 2899 5146Shenzhenphone +86 755 8974 8558fax +86 755 8974 8560Tokyo, Japanphone +81 3 6408 2369fax +81 3 5449 7202www.chomerics.comwww.parker.comCHOMERICS, CHO-FORM, CHO-SEAL, CHO-SIL, COMBO-STRIP, POLASHEET, POLASTRIP, SOFT-SHIELD, SPRING-LINE, SPRING-MESH are registered trademarks of Parker Hannifin Corporation. MESH-STRIP is a trademark of Parker Hannifin Corporation.Other trademarks are the property of their respective owners.© 2008 Parker Hannifin Corporation. All rights reserved.Literature Number: CHO CAT 1002 EN 2/0810M - BRRChomericsENGINEERING YOUR SUCCESS.