Table Of Contents
Key Points
- Designing a radio frequency gasket is a complex and challenging task.
- There are thousands of materials to choose from and getting it right the first time is critical in saving you time and money.
- Use this guide to get familiar with the types of materials that may suit your needs.
Radio frequency (RF) gaskets play a crucial role in ensuring the reliable functioning of electronic devices and systems. They are designed to prevent unwanted signal leaks and protect against electromagnetic interference (EMI) and radio frequency interference (RFI). With the increasing demand for high-speed, high-performance electronic systems, RF gaskets are becoming increasingly important.
In this blog, we will explore the various materials used in the production of RF gaskets and their properties, so you can get off on the right food in selecting the right gasket material for your application.
If you want the best, you need to work with the best. Modus Advanced is a leader in RF gasket solutions for a wide variety of industries–contact us today to learn more.
What is a Radiofrequency (RF) Gasket?
A radio frequency (RF) gasket is a type of gasket used to provide electromagnetic interference (EMI) shielding in electronic devices. RF gaskets are used to prevent unwanted radio frequency signals from entering or leaving a device, and to prevent EMI from affecting the performance of the device.
There are various types of RF gaskets available, including conductive and non-conductive gaskets. The choice of gasket material depends on the specific requirements of each application, including the frequency range, size and shape of the equipment to be shielded, and the environment in which the equipment will be used.
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RFI vs EMI
It’s worth quickly noting the differences between RF and EMI as they are often used interchangeably. RF and EMI are related but distinct concepts in electronics. In most cases however, if you need to protect a device from one, you need to protect that same device from the other.
RF refers to the frequency range of electromagnetic signals used for communication, such as radio and television broadcasts, cell phone signals, and Wi-Fi.
EMI, on the other hand, refers to the interference caused by these signals on other electronic devices. EMI is a disturbance that affects an electrical circuit due to either electromagnetic induction or electromagnetic radiation emitted from an external source. It can cause malfunctions or degrade the performance of electronic systems and devices.
RF Gaskets in the Wild
RF gaskets are a type of EMI shielding solution used in various industries, including aerospace and defense, medical devices, and emerging technology. Choosing the correct materials for your RF gasket in any of these industries is critical to the effectiveness of the device.
In the aerospace and defense industries, RF gaskets are used to protect sensitive electronic systems, such as avionics, navigation systems, and communication equipment. They help ensure that these systems will continue to function as intended and support mission success, even in the presence of potential EMI from electronic countermeasures or other sources.
In the medical device industry, RF gaskets are used to protect sensitive medical equipment, such as electronic implants and medical imaging systems. They help ensure the safety and reliability of these devices, even in the presence of potential EMI from other electronic devices.
In the emerging technology industry, RF gaskets are used to protect cutting-edge electronic devices, such as wearable technology and Internet of Things (IoT) devices. They help to ensure the performance and reliability of these devices, even in the presence of potential EMI from other electronic devices.
RF gaskets play a critical role in the performance and reliability of electronic devices across a range of industries. By choosing the correct material(s) for your RF gasket, you are preventing the escape of electromagnetic signals and protecting against external EMI, to ensure that electronic devices will continue to function as intended and support mission success.
RF Gasket Material Questions
Before you get started in choosing a material for your custom gasket, there are 10 key questions you should ask yourself to steer the ship:
- Will the gasket be used in an indoor or outdoor application?
- What temperature range must your gasket operate in?
- What does your industry require?
- How hard or soft does your gasket material need to be?
- Do you need a three-dimensional or flat gasket?
- How will your custom gasket be assembled?
- What will your housing be made out of?
- What chemicals will the gasket be exposed to?
- How small is the gasket?
- Is outgassing a concern?
These questions are a great launching point for choosing your gasket material. They will help you balance cost, lifespan, and the needs of your design. Once you’ve answered these ten questions you’re well on your way to a successful design. Selecting the right gasket material is as much of a science as it is an art, aso do it with a trusted partner (we’re ready when you are!).
What Are RF Gaskets Made From?
RF gaskets are typically made from a combination of conductive and non-conductive materials. The conductive component is typically made from a metal, such as copper or nickel, which provides the electrical conductivity necessary for EMI shielding. The non-conductive component is typically made from a flexible material, such as silicone or neoprene, which provides a seal to prevent the ingress or egress of unwanted radio frequency signals.
Other materials that may be used in RF gaskets include conductive elastomers, conductive foams, and metal-filled plastics. The specific materials used in an RF gasket will depend on the requirements of the application, such as the operating temperature range, frequency range, and level of shielding performance required.
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Conductive vs. Non-Conductive Materials
Conductive RF gasket materials are materials that are used in the construction of RF gaskets and provide the electrical conductivity necessary for effective EMI shielding. Some common conductive materials used in RF gaskets include:
- Copper: Copper is a highly conductive metal that is often used in RF gaskets due to its high electrical conductivity and durability.
- Nickel: Nickel is another conductive metal that is often used in RF gaskets. It has similar properties to copper but is less expensive and easier to work with.
- Silver: Silver is the most conductive metal and is often used in high-performance RF gaskets. However, it is also the most expensive of the common conductive materials used in RF gaskets.
- Conductive Elastomers: Conductive elastomers are a class of materials that combine the electrical conductivity of metals with the flexibility of elastomers. They are often used in RF gaskets due to their ability to provide both electrical conductivity and sealing performance.
- Conductive Foams: Conductive foams are a type of foam that is infused with conductive particles. They are often used in RF gaskets due to their ability to provide both electrical conductivity and compression resistance.
The specific conductive material used in an RF gasket will depend on the requirements of the application, such as the operating temperature range, frequency range, and level of shielding performance required.
Non-conductive RF gasket materials are materials that are used in the construction of RF gaskets and provide the sealing function to prevent the ingress or egress of unwanted radio frequency signals. Some common non-conductive materials used in RF gaskets include:
- Silicone: Silicone is a flexible, high-temperature resistant material that is often used in RF gaskets due to its ability to provide both sealing and insulation performance. Silicone is a popular choice for non-conductive RF gasket materials due to its excellent electrical insulation properties, high temperature resistance, and resistance to chemicals and UV radiation. It is also highly compressible and provides good sealing performance.
- Neoprene: Neoprene is a synthetic rubber material that is often used in RF gaskets due to its ability. It is also highly flexible and has good compression set resistance.
EPDM: EPDM is another type of synthetic rubber material that is often used in RF gaskets due to its ability to provide good sealing performance and resistance to ozone, heat, and weathering. - Fluorosilicone: Fluorosilicone is a type of silicone material that is often used in RF gaskets due to its ability to provide both sealing and high-temperature resistance performance.
- Sponge Rubber: Sponge rubber is a versatile type of rubber material that is often used in RF gaskets due to its ability to provide good sealing performance and compression resistance. It is easy to shape, lightweight, and low in cost.
- Foam: Foam materials are widely used in non-conductive RF gaskets due to their excellent resilience, low cost, and ease of fabrication. They offer excellent electrical insulation properties and can be made in various densities to meet specific application requirements.
The specific non-conductive material used in an RF gasket will depend on the requirements of the application, such as the operating temperature range, frequency range, and level of sealing performance required.
When selecting non-conductive RF gasket materials, it is important to consider factors such as temperature resistance, chemical compatibility, and compression set resistance to ensure that the gasket will perform effectively over time.
With a variety of materials available, finding the right one for your application is key to ensuring reliable performance and protection against EMI and RFI.
Manufacturing Method
Designing for manufacturability is a huge piece of the puzzle when it comes to producing a RF gasket. Your design may sound good on paper but it may be just a hair short of perfect. Working with an expert engineering team who understands DfM can help avoid the headache of getting it wrong.
One of the most important parts of designing for manufacturability is what method will be required to manufacture your gasket.
There are multiple processes by which a custom RF gasket can be made, including:
The material you select and the design requirements will help to narrow down which process can be used to optimally manufacture your gasket.
And each process comes with different costs. For instance, waterjet cutting is typically much more expensive than die cutting but allows you to create gaskets with perfectly straight walls and almost no deflection. Understanding where you can change your design, and what is non-negotiable, may help you utilize different manufacturing processes to produce it.
The Bottom Line
Designing a custom RF gasket is no easy task, and doing it in concert with a professional is highly recommended. There are many things to take into consideration when choosing your gasket material and getting it wrong can have serious consequences, everything from loss of functionality to loss of life. Getting it right the first time is paramount.
As a trusted partner to businesses in a variety of industries, Modus Advanced is uniquely qualified to support custom RF gasket production–prototyping and beyond. Contact us today to get started.
