Modern industrial air compressor systems rely on effective enclosure sealing to protect sensitive electronics and HMI (Human machine interface) units from dust and moisture ingress. However, achieving IP65 / NEMA 4 protection can become challenging when the sealing material also needs to work within compact, low-force mounting systems.
A manufacturer of industrial air compressor systems approached Silicone Engineering during the development of a new sheet metal enclosure featuring an integrated HMI unit.
The Opportunity & Challenge
The seal needed to provide reliable IP65 / NEMA 4 environmental protection while operating within a restricted installation space using a spring-loaded clip mounting system.
As the gasket compressed, the resulting compression force risked exceeding the available spring force of the mounting clips, preventing the HMI unit from installing correctly.
Initial testing with low-density EPDM sponge rubber showed that even soft EPDM materials generated excessive compression force for the application.
The customer also required:
- A closed-loop sealing solution
- Low compression force
- Long-term environmental sealing performance
- Compatibility with restricted installation tolerances
- A design suitable for series production
The Solution
Following prototype discussions and design reviews, Silicone Engineering worked closely with the customer to help refine the sealing concept and material selection.
The final solution centred around expanSil™ GP200 closed-cell silicone sponge, selected for its lower compression characteristics and long-term sealing performance compared with traditional elastomer materials.
The project explored several manufacturing options, including compact extrusion profiles, vulcanised spliced loops, and die-cut gasket alternatives, while CFD and force analysis calculations helped optimise compression performance across the sealing path.
Compared with EPDM, closed-cell silicone sponge provided improved compression set resistance, environmental durability, and consistent sealing performance for the application.
By collaborating during the prototype phase, Silicone Engineering was able to help guide the project from concept through to production-ready sealing solutions suitable for HVAC and industrial enclosure applications.
Looking for a low force sealing solution?
Silicone Engineering manufactures a wide range of closed-cell silicone sponge extrusions and sheeting materials designed for environmental sealing applications requiring low compression force, IP-rated protection, and long-term reliability.
Whether your application involves HVAC systems, industrial enclosures, electronics, or transportation equipment, our team can help guide you towards the right silicone material solution.
