Electrically Conductive Elastomers Gaskets

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Electrically Conductive Elastomers (ECE)

Electrically conductive elastomer gaskets are critical engineered components designed to solve two fundamental challenges in modern electronics: providing reliable Electromagnetic Interference (EMI) / Radio Frequency Interference (RFI) shielding and ensuring robust environmental sealing. By integrating conductive fillers within a flexible elastomeric matrix, these advanced conductive elastomers protect sensitive devices from interference while sealing out dust, moisture, and other contaminants.

Understanding the Technology: How Conductive Elastomers Work?

Conductive Elastomer Composition

A conductive elastomer gasket is a composite material. Its functionality arises from a homogeneous dispersion of conductive particles—such as silver, silver-coated copper, nickel, or carbon—within a base elastomer like silicone or fluorosilicone. When the filler concentration reaches a critical threshold (the percolation point), a three-dimensional conductive network forms throughout the material.

Principle of Operation

This network allows the gasket to function as a conductive barrier. When mounted between two surfaces, a properly designed conductive elastomer gasket:

Creates a continuous electrical path to ground, dissipating EMI energy.
Reflects and absorbs incident electromagnetic waves.
Compresses to fill gaps, providing a hermetic or environmental seal against particles and fluids.

Why Choose Conductive Elastomers?

Compared to metal stampings or conductive fabrics, electrically conductive elastomers offer superior design flexibility, better compensation for surface irregularities, and the unique combination of shielding and sealing in a single part, reducing assembly complexity and cost.

Core Performance Specifications

Selecting the right conductive elastomer gasket requires understanding key performance parameters. The table below outlines typical specifications for our electrically conductive elastomers.

Parameter	Typical Value / Range	Test Standard	Importance for Design
Shielding Effectiveness (SE)	65 dB to >120 dB (30 MHz - 10 GHz)	ASTM D4935, MIL-DTL-83528	Primary measure of EMI/RFI attenuation. Higher dB = better shielding.
Volume Resistivity	0.001 to 10.0 Ω·cm	ASTM D991	Defines bulk conductivity of the conductive elastomer material itself.
Compression Force Deflection	5 to 80 psi (25% deflection)	ASTM F36	Force required to compress; critical for enclosure and fastener design.
Compression Set	5% to 25% (22 hrs @ 70°C)	ASTM D395	Indicates elastic recovery and long-term sealing capability.
Operating Temperature Range	-55°C to +200°C (Continuous)	MIL-STD-202	Determines suitability for harsh environments.
Fluid & Environmental Resistance	Resistant to weathering, oxidation, many solvents	Various	Ensures longevity; fluorosilicone conductive elastomers offer superior fuel/oil resistance.

Types of Conductive Elastomer Gaskets

Our conductive elastomers are available in multiple forms to meet specific application demands.

Solid Electrically Conductive Elastomer Extruded Gaskets

Dense, homogeneous profiles (round, D-shaped, rectangular) created through an extrusion process. The most common type of conductive elastomer gasket.

Applications requiring maximum shielding performance and superior environmental sealing (IP68 achievable). Ideal for metal enclosures in telecom, industrial, and military use.

Electrically Conductive Elastomer Co-Extruded Gaskets

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Die-Cut EMI Shielding Elastomer Gaskets

Flat conductive elastomer sheets converted into custom shapes via die-cutting processing, enabling tight tolerances and rapid customization.

Thin, space-constrained designs and cost-effective EMI sealing solutions for consumer electronics, communication devices, and industrial control assemblies.

Custom Molded Electrically Conductive Elastomers

Complex 2D or 3D shapes produced in precision molds. This process creates a conductive elastomer gasket that perfectly fits irregular geometries.

High-volume applications with unique space constraints, such as automotive sensor housings, medical device connectors, and aerospace avionics.

Zebra Connectors

Strip connectors consisting of alternating conductive/non-conductive silicone layers. Primarily used for electrical interconnection between flat surfaces (e.g., LCD to PCB).

Providing anisotropic conductivity (vertical conduction only) in display and touch panel assemblies. Note: Function is interconnection, not EMI shielding.

Conductive Silicone Foam Gasket

A softer, compressible foam core made electrically conductive through filler loading or by lamination with conductive fabric.

Applications with low closure force requirements, uneven surfaces, or lightweight plastic housings. Common in consumer electronics and handheld devices.

Industry-Specific Applications & Solutions

Automotive & Electric Vehicles (EV)

Electrically conductive elastomers are vital in EVs for shielding high-voltage battery management systems (BMS), onboard chargers, and ADAS sensors from EMI, while also sealing against underhood fluids and weather. Our conductive elastomer gasket solutions meet AEC-Q200 reliability standards.

Telecommunications & 5G Infrastructure

Base station cabinets, RRUs, and network equipment use conductive elastomers to contain internal EMI and prevent signal degradation, ensuring network integrity. Materials are optimized for shielding effectiveness across broad frequency ranges, including mmWave.

Medical & Diagnostic Equipment

MRI machines, patient monitors, and surgical devices require electrically conductive elastomer gaskets that provide shielding in sensitive environments, often with added requirements for biocompatibility (ISO 10993) and low outgassing.

Aerospace, Defense, & Industrial

In these mission-critical sectors, conductive elastomers must perform under extreme conditions of temperature, vibration, and pressure. Our products are engineered to meet stringent standards like MIL-DTL-83528 for long-term reliability.

Design Support & Customization Services

We specialize in engineering custom conductive elastomer gasket solutions. Our technical team supports you from concept to production.

Our Customization Capabilities

Material Development: Tailoring filler type, loading percentage, and polymer base (silicone, fluorosilicone) to achieve specific electrical, mechanical, or chemical resistance properties.
Profile & Shape Design: Expert die design for complex extrusions or precision tooling for molded electrically conductive elastomers.
Adhesive Integration: Applying pressure-sensitive adhesives (PSA) with precise tolerances for simplified installation.
Value-Added Services: Die-cutting, splicing, kitting, and packaging to your specifications.

The Collaboration Process

Application Review: We analyze your EMI, environmental, spatial, and cost requirements.
Material & Form Recommendation: We propose the optimal conductive elastomer type and specifications.
Prototyping: We produce functional samples for your testing and validation.
Production & QA: We move to volume manufacturing with strict quality control.

Frequently Asked Questions

What is the primary difference between EMI shielding and environmental sealing in a conductive elastomer gasket?

While both functions are integrated, shielding refers to the conductive elastomer's ability to attenuate electromagnetic energy via its conductive network. Sealing refers to the base elastomer's ability to physically block the ingress of environmental elements when compressed. A high-performance conductive elastomer gasket excels at both.

How do I ensure good EMI performance from an electrically conductive elastomer gasket?

Three factors are critical: 1) Surface Preparation: The mounting surfaces must be clean, conductive, and free of non-conductive coatings like paint or anodization. 2) Adequate Compression: The conductive elastomer must be compressed to its designed deflection (typically 15-30%) to ensure continuous metal-to-metal contact. 3) Proper Flange Design: The enclosure flange must be stiff enough to apply even pressure without warping.

Can conductive elastomers be made thermally conductive as well?

Yes. Hybrid materials can be formulated by combining electrically conductive fillers (e.g., silver) with thermally conductive fillers (e.g., alumina, boron nitride). This creates a multi-functional conductive elastomer gasket that manages both EMI and heat dissipation.

What are the key factors affecting the long-term reliability of these gaskets?

The longevity of electrically conductive elastomers depends on resistance to compression set (loss of elasticity), environmental aging (exposure to ozone, UV, temperature cycles), and galvanic corrosion (when in contact with dissimilar metals). Selecting the correct base elastomer and filler chemistry for your environment is essential.