P R O D U C T I N F O R M A T I O N

Information About Resin Designs ® Brand

Electrically Conductive Materials
Long-term, reliable protection of sensitive circuits and Gel Rope Gaskets
components is important in today’s delicate and demanding Type
electronics applications. Resin Designs ® shielding gaskets Precured gel with circular Monel wire mesh formed in a circu-
and Resin Designs ® gel rope gaskets are designed to deliver lar cross section
by providing shielding and effective grounding of high- Physical Form
energy electromagnetic interference (EMI). Resin Designs ® Knitted circular Monel wire mesh that is impregnated with a
conductive gaskets provide dependable, cost-effective silicone gel and precured
corrosion protection for aircraft skin and antennas. These Special Properties
products have the unique capability of wetting to and EMI shielding, corrosion protection, environmental sealing
against galvanic corrosion, pressure sealing, in a single easy-to-
sealing a surface on contact. Moisture and electrolytes are apply product, -40 to 150°C operating temperature
displaced by the soft gel that stops galvanic corrosion of
Potential Uses
dissimilar metal surfaces. These products thus provide either Shielding and effective grounding of high energy EMI
EMI shielding or grounding along with sealing in a single
product. Shielding Gaskets
Type
Gel Rope Gaskets Precured gel with Monel wire cloth precision cut to shape
Resin Designs gel rope gaskets provide shielding against
high levels of EMI, environmental and pressure sealing Physical Form
against water ingress and electrical grounding in a variety Woven Monel wire cloth that is impregnated with a standard
of electronics and communications applications. Extensive
salt fog tests have shown that the Resin Designs silicone Special Properties
gel material provides an effective barrier against galvanic Electromagnetic interference (EMI) shielding, corrosion pro-
tection, environmental sealing, pressure sealing, in a single easy-
corrosion. Gel surrounds the conductive wire mesh of the to-apply product; -40 to 125 or 150°C operating temperature
Resin Designs gaskets and isolates the metal substrate-to-
Potential Uses
gasket contact points from corrosive elements. The unique Shielding and effective grounding of high energy EMI
wire mesh/silicone gel construction also ensures that the
Conductive Gaskets
electrical resistance of the wire mesh will not increase
Type
the gel not only minimizes intermetallic corrosion between
gasket and substrate, but also ensures dependable EMI
shielding and environmental sealing over time. Physical Form
Woven aluminum alloy wire cloth impregnated with a high-
Standard Resin Designs gaskets feature wire mesh made of
Monel®, ideal for its EMI shielding and low cost. Special Properties
Electrical grounding; reduced installation time with precured gel
Shielding Gaskets sealant; no cure required; easy removal and repair; cost effective
The unique Resin Designs shielding gaskets provide shield- Potential Uses
ing and effective grounding of high energy EMI. Extensive Corrosion-protected grounding for aircraft skin and antennas

shown that Resin Designs gel gaskets provide an effective

at temperatures between -40 and 150°C. Gel gaskets can
barrier against corrosion. This patented product made of
also withstand differential pressures up to 30 psi at room
temperature.
irregular surfaces to protect them from corrosive elements.
Resin Designs gel gaskets provide corrosion protection Resin Designs gaskets consist of a woven Monel wire
cloth (30 or 60 mesh) that is impregnated with a standard

for applications that require resistance to solvents and fuels.

The conductive Monel cloth is an alloy of nickel and copper,

or AMS-4730. Sheet stock is available in standard sizes of

7 x 8, 7 x 15 and 23 x 23 inch sheets. Custom sheet sizes are
PRODUCT INFORMATION

Resin Designs®
Brand Product Description Features
Gel Rope Gaskets
EMI-CSI-M3 EMI Commercial-grade, precured silicone gel with Monel circular Pressure sealing, precured gel; standard wire sizes from 0.063"
Gel Rope Gaskets knit rope to 0.250"; operating service temperatures -40 to 150°C

Shielding Gaskets
EMI-FS-M2
Shielding Gaskets 60 mesh Monel wire cloth solvents and fuels; wets and seals most surfaces on contact;
standard size of 24" x 24" and custom sizes available upon
request; protects at temperatures between -40 and 150°C
EMI-FS-M5
Shielding Gaskets 30 mesh Monel wire cloth solvents and fuels, wets and seals most surfaces on contact;
standard size of 24" x 24" and custom sizes available upon
request; protects at temperatures between -40 and 150°C
EMI-TGSI-M2 Shielding, grounding and environmental sealing; high- Pressure sealing; precured high performance silicone gel, wets
Shielding Gaskets performance silicone; 60 mesh Monel wire cloth and seals most surfaces on contact; standard size of 24" x 24"
and custom sizes available upon request; protects at
temperatures between -40 and 150°C
EMI-TGSI-M5 Shielding, grounding and environmental sealing; high- Pressure sealing; precured high performance silicone gel, wets
Shielding Gaskets performance silicone; 30 mesh Monel wire cloth and seals most surfaces on contact; standard size of 24" x 24"
and custom sizes available upon request; protects at
temperatures between -40 and 150°C
Conductive Gaskets
GND-FS-A1 GND conductive gaskets for electrical grounding and corrosion Cost effective corrosion protection; reduced installation time;
Grounding Gaskets prevention; 16 x 18 mesh aluminum alloy wire cloth

contaminants; metal mesh incorporated for electrical bonding

Resin Designs ®
Brand Product Potential Uses Application Methods
Gel Rope Gaskets
EMI-CSI-M3 EMI Electromagnetic interference (EMI) shielding and DC Cold-applied without any special surface preparation or
Gel Rope Gaskets grounding, environmental sealing against galvanic corrosion adhesive, the gel’s self-healing characteristic eliminates the need
to fuse the ends together to form a gasket
Shielding Gaskets
EMI-FS-M2 Shielding and effective grounding of high energy EMI; stops Cold-applied without any special tools or cure time; gaskets are
Shielding Gaskets galvanic corrosion of dissimilar metal surfaces for up to 1000
hours in salt spray; seals up to 30 psid pressure

EMI-FS-M5
Shielding Gaskets

EMI-TGSI-M2
Shielding Gaskets

EMI-TGSI-M5
Shielding Gaskets

Conductive Gaskets
GND-FS-A1 Corrosion protection for aircraft skin and antennas; metal mesh
Grounding Gaskets provides electrical bonding that dissipates static charges and precured gel gaskets to bare metal; no special tools, cure time or
lightning strikes special coating are necessary
TYPICAL PROPERTIES

DC Resistance Shielding Effectiveness

MIL-STD-202, Method 106,

Endurance 48 hr at 156°C,

Initial, 100 to 1000 MHz,

After Humidity Cycling,
After High Temperature

After Salt Fog, 1000 hr,

After Salt Fog, 1000 hr,

After Thermal Cycling

Initial, 10 to 100 MHz,

After Salt Fog, 500 hr,
-55 to 125°C, 5 cycles,
Initial, mΩ maximum

100 to 1000 MHz,

After Heat Aging
168 hr at 150°C,

10 to 100 MHz,
mΩ maximum
mΩ maximum

mΩ maximum

mΩ maximum

mΩ maximum

dB minimum

dB minimum
dB minimum

dB minimum
Resin Designs ®
Brand Product
Gel Rope Gaskets
EMI-CSI-M3 5 5 5 5 – – 90 70 80 70
EMI Gel Rope
Gaskets
Shielding Gaskets

EMI-FS-M2 3 31 32 33 – – 90 90 80 80
Shielding Gaskets
EMI-FS-M5 3 31 32 33 – – 90 90 80 80
Shielding Gaskets
EMI-TGSI-M2 3 3 3 3 – – 90 90 80 80
Shielding Gaskets
EMI-TGSI-M5 3 3 3 3 – – 90 90 80 80
Shielding Gaskets
Conductive Gaskets

GND-FS-A1 1 11 12 13 1 1 – – – –
Grounding
Gaskets
1
168 hr at 175°C.
2
-55 to 150°C, 5 cycles.
3
48 hr at 187°C.
Gaskets
Gaskets

Grounding
EMI-FS-M5
EMI-FS-M2

GND-FS-A1
EMI-CSI-M3
EMI Gel Rope

EMI-TGSI-M5
EMI-TGSI-M2
Resin Designs ®
Brand Product

Shielding Gaskets
Shielding Gaskets
Shielding Gaskets
Shielding Gaskets
Gel Rope Gaskets

Shielding Gaskets

Conductive Gaskets

2
3
3
3
3
3
Mechanical Strength, lb minimum

Sealing Performance,

–
–
–
–
–
No
Leaks
30 psig for 1 min

–
–
–
–
–
HB
Flammability, UL 94

Hydraulic Fluid, Skydrol ® 500,

Pass
Pass
Pass
Pass
Pass
Pass
35 min at 85°C

Lubricating Oil, MIL-L-23699,

Pass
Pass
Pass
Pass
Pass
Pass
35 min at 120°C

Diluted Cleaning Fluid, MIL-C-

–
Pass
Pass
Pass
Pass
Pass

87937B, Type II, 35 min at 65°C

Deicing Fluid, MIL-A-8243,

–
–
–

Pass
Pass
Pass 35 min at 65°C

Hydraulic Fluid, MIL-H-5606

–
–
–

Pass
Pass
Pass

35 min at 85°C

Coolanol® 25,

–
–

Pass
Pass
Pass

30 min at 175°C
<25%

Lubricating Oil, MIL-L-

–
–
–

Pass
Pass
Pass

7808, 35 min at 120°C

Cee Bee® Brand Cleaner,

–
–
–
–
–

Pass
35 min at 65°C

Aviation Fuels, JP-5/JP-4 (MIL-

Fluid Resistance, Maximum Weight Change

–
–
–

Pass
Pass
Pass

T-5624), JET A, 35 min at 25°C

IPA 25% by Volume in Mineral

–
–
–

Pass
Pass
Pass

Spirits, 25 min at 25°C

Gasoline, MIL-G-3056, Type I,

–
–
–

Pass
Pass
Pass

25 min at 25°C

Propylene Glycol, Type II,

–
–
–
–
–

Pass

25 min at 25°C
also available up to 24 x 96 inches. Custom gasket shapes
can be readily designed and precision stamped to customer
Resin Designs’ conductive gel gaskets provide an effective
barrier against corrosion. The gel sealant provides excellent
Conductive Gaskets
interfacial sealing and has been formulated to withstand
Resin Designs conductive gaskets provide dependable, aviation fuels and other liquid contamination. The aluminum
cost-effective corrosion protection for aircraft skin and wire cloth incorporated in the gasket provides electrical
antennas – protection so good that corrosion repair costs bonding that dissipates static charges and lightning strikes.

Supplied ready-to-use, the precured gel gaskets are cold- subsonic trials with up to 12 months between inspections.
applied to bare metal for easy, one-step installation. The Unlike conventional sealants, the gel gasket remains soft
installation requires no special tools, no cure time and no and pliable throughout its service life. No special tools are
additional coatings. Gaskets are precision cut and supplied required to remove the antenna or the gasket during antenna
inspection, minimizing the risk of damaging the aircraft skin
Resin Designs conductive gaskets are fabricated using an during antenna maintenance. Aircraft skin exposed to the gel
aluminum wire cloth impregnated with a high-performance, sealant is easily prepared for aircraft painting with industry-
standard cleaning procedures and solvents.

Table I: Resin Designs Gel Rope Gasket Dimensions (Refer also to Figure 1.) Figure 1. Gasket and Mesh Design
Gasket Diameter (A) , inch (mm)
1
Wire Mesh Diameter (B) , inch (mm)
1

Nominal Size2 Min. Max. Min. Max.

1.6 [.063] 2.0 [.078] 2.2 [.087] 1.7 [.068] 1.9 [.075]
2.4 [.094] 3.0 [.119] 3.3 [.130] 2.8 [.109] 3.0 [.119]
3.2 [.125] 3.5 [.136] 4.2 [.166] 3.5 [.136] 4.0 [.156]
4.0 [.156] 4.8 [.188] 5.2 [.204] 4.3 [.171] 4.7 [.185]
4.8 [.188] 5.2 [.204] 6.0 [.235] 5.1 [.200] 5.6 [.219]
6.4 [.250] 6.8 [.269] 7.6 [.300] 6.6 [.260] 7.1 [.281] B
A

A
B
1
Wire mesh and gasket diameters are actual dimensions under no compression load.
2
Nominal size is wire mesh diameter compressed under a 4-oz load.

Figure 2. Optimized Gel Rope Gasket Design Figure 3. One-Piece Design

Tolerances of +0.003 inch (0.07 mm) The gel rope gasket eliminates the need for a two-piece en-
vironmental seal and wire mesh gasket.

2.0 ˚ 2.0 ˚
EMI Gel Rope Gasket
Environmental
R0.005 typ .

D
C

A B

Table II: Gel Rope Gasket Design Dimensions (Refer also to Figure 2.)
Rope Gasket Size Required Groove Dimensions, inch (mm)
Nom. Diameter, inch (mm) A B C D
0.063 (1.6) 0.039 (0.99) 0.040 (1.02) 0.048 (1.22) 0.083 (2.11)
0.094 (2.4) 0.061 (1.55) 0.063 (1.60) 0.075 (1.91) 0.130 (3.30)
0.125 (3.2) 0.078 (1.98) 0.080 (2.03) 0.096 (2.44) 0.166 (4.22)
0.156 (4.0) 0.093 (2.36) 0.096 (2.44) 0.115 (2.92) 0.199 (5.05)
0.188 (4.8) 0.109 (2.77) 0.112 (2.84) 0.135 (3.43) 0.233 (5.92)
0.250 (6.4) 0.140 (3.55) 0.144 (3.66) 0.172 (4.37) 0.298 (7.57)
INSTALLATION Figure 4. Gel Rope Gasket Installation
Resin Designs Gel Rope Gasket Materials
The Resin Designs gel rope gasket sticks easily in both
hot and cold environments, without any special surface
preparation or adhesive. Because the gel in the gasket is
precured, there is no delay due to a lengthy cure cycle, and A. Too short
no heating or special tools are needed for installation. The
gel’s self-healing characteristic eliminates the need to fuse
the ends together to form a gasket.
The Resin Designs gel rope gasket offers environmental
B. Too long
sealing and EMI protection when the gasket is installed in a
housing with the recommended tongue and groove design.
0.15" (3.8 mm)
In order to perform properly, the gel gasket must be placed
in the groove. Figure 2 shows a sketch of an optimized de-
sign of the tongue and groove (protrusion) for gel gaskets.
Table II provides the required groove dimensions for each C. Proper length
rope gasket size.

This design ensures that the gasket stays in the groove after
opening of the housing cover and that excellent sealing is
achieved. This design also prevents overcompression of the D. Installed butt joint
gasket during installation.

In order to seal, the gasket has to be under compression.

Typical compression should be 20 to 40 percent of the gel The drawings (A–D) in Figure 4 show four typical installa-
gasket outside diameter. The optimized groove dimensions tion scenarios during gel gasket installation:
provide for the recommended compression. The level of • 4A shows a gasket cut too short, resulting in an installa-
compression determines sealing performance. tion that will produce a poor seal.
• 4B shows a gasket cut too long. If the overlap is too long
To install: the gasket will buckle up. To correct this, cut a small
• Clean dirt from tongue and groove. section of the gasket at one of the ends and create a new
• With a sharp tool (such as a scissors) cut the gel gasket butt joint.
perpendicular to the axis of the gasket (see Figure 4). • 4C shows the proper length of gasket just before instal-
• Press one end of the gasket into the groove. Important: lation. The small overlap (0.15" max.) is necessary to
Start the installation on the straight section of the groove, create a butt joint under axial compression. Compress the
not on the curved section. end of the gasket in the direction of the arrow and press it
• Continue pressing the gasket into the groove, clockwise into the groove to create the butt joint.
or counterclockwise, working from one end to the other. • 4D shows the correct installation and butt joint.

Figure 5. Shielding Effectiveness of Gel Rope Gaskets, 1

of
Initial and After 1000 hr Salt Fog Test Gel Rope Gaskets

140 40

120 0.250" (after 1000 hr) 35

0.250"
Shielding Effectiveness, dB

0.188" 30
100 0.156" 0.063"
Compression Force, lb

0.125"
80 0.094" 25 0.094"
0.063" (after 1000 hr)
0.063" 0.125"
60 20
0.156"
15 0.188"
40
.0250"
20 10

0 5
10 20 40 60 80 100 200 400 600 800 1000
0
Frequency, MHz
10 20 30 40 50
Compression, %
1
Designs of rectangular groove should provide for 20 to 40% compression of the gasket diameter.
The optimized tongue and groove design dimensions already provide for the recommended
compression.
Product Nomenclature and Packaging – Gel Rope Gaskets
Part Numbering System

EMI - XX - XX - XXXX - XXXX

Nominal Rope Gasket Diameter – Standard Reel Length
0063 = 0.063 inch (1.6 mm) – R500 = 500 ft (152 m) or R1500 = 1500 ft (457 m)
0094 = 0.094 inch (2.4 mm) – R200 = 200 ft (61 m) or R1000 = 1000 ft (305 m)
0125 = 0.125 inch (3.2 mm) – R200 = 200 ft (61 m) or R750 = 750 ft (228 m)
0156 = 0.156 inch (4.0 mm) – R100 = 100 ft (30 m) or R500 = 500 ft (152 m)
0188 = 0.188 inch (4.8 mm) – R125 = 125 ft (38 m) or R350 = 350 ft (106 m)
0250 = 0.250 inch (6.4 mm) – R150 = 150 ft (45 m) or R250 = 250 ft (76 m)

Metal Type
M3 = Monel circular knit rope

Gel Type
CSI = Commercial-grade silicone

Product Nomenclature and Packaging – Shielding Gaskets

Part Numbering System

EMI-XX-XX-XXXX
Gel Type Standard sheet gasket (M2 and M5 gaskets)
FS = Fluorosilicone Refers to standard and custom sheet gasket size examples:
TGSI = High-performance silicone 6000 = 7 inch x 8 inch
6001 = 7 inch x 15 inch
6003 = 24 inch x 24 inch
Metal Type
M2 = Monel #60 (60-mesh woven Monel wire cloth; Custom sheet gasket (M2 and M5 gaskets)
wire diameter 0.0075 inch nominal); Refers to a Resin Designs specification control drawing.
Monel wire cloth thickness = 0.015 inch nominal; Gaskets are die-cut at the factory to a specific customer requirement.
product thickness = 0.026 inch nominal
M5 = Monel #30 (30-mesh woven Monel wire cloth;
wire diameter 0.011 inch nominal);
Monel wire cloth thickness = 0.026 inch nominal;
product thickness = 0.044 inch nominal

Product Nomenclature and Packaging – Conductive Gaskets

Part Numbering System

GND-FS-A1-YY-xxxxxxxxxxxx

Antenna model number

Antenna manufacturer code

Aluminum 5154, 24"x 36" mesh woven wire cloth, wire dia. 0.010" nominal, product thickness 0.032" nominal

Gel Type
FS = Fluorosilicone

Notes:
Resin Designs supplies precut gaskets for most industry-standard antennas.
Upon request, Resin Designs will quote on any gasket drawing a customer sup-
plies. For nonstandard gasket shapes, Resin Designs’ quotation may include a
non-recurring engineering charge.

Templates of existing and proposed gasket shapes are available upon request
STORAGE AND SHELF LIFE LIMITED WARRANTY INFORMATION
Because these are precured materials, there is no special – PLEASE READ CAREFULLY
storage condition or usage date required. The product The information contained herein is offered in good faith
should be stored in the original packaging under normal and is believed to be accurate. However, because conditions
warehouse conditions to maintain the integrity of the and methods of use of our products are beyond our con-
packaging materials. trol, this information should not be used in substitution for
customer’s tests to ensure that Resin Designs’ products are
LIMITATIONS safe, effective, and fully satisfactory for the intended end
These products are neither tested nor represented as suitable use. Suggestions of use shall not be taken as inducements to
for medical or pharmaceutical uses. infringe any patent.

SAFE HANDLING INFORMATION Resin Designs’ sole warranty is that the product will meet
the Resin Designs sales specifications in effect at the time of
PRODUCT SAFETY INFORMATION REQUIRED FOR
shipment.
SAFE USE IS NOT INCLUDED IN THIS DOCUMENT.
BEFORE HANDLING, READ PRODUCT AND
Your exclusive remedy for breach of such warranty is limit-
MATERIAL SAFETY DATA SHEETS AND CONTAINER
ed to refund of purchase price or replacement of any product
LABELS FOR SAFE USE, PHYSICAL AND HEALTH
shown to be other than as warranted.
HAZARD INFORMATION. THE MATERIAL SAFETY
DATA SHEET IS AVAILABLE ON THE RESIN DESIGNS
RESIN DESIGNS SPECIFICALLY DISCLAIMS
WEBSITE AT WWW.RESINDESIGNS.COM, OR FROM
ANY OTHER EXPRESS OR IMPLIED WARRANTY
YOUR RESIN DESIGNS REPRESENTATIVE, OR
OF FITNESS FOR A PARTICULAR PURPOSE OR
DISTRIBUTOR.
MERCHANTABILITY.

HEALTH AND ENVIRONMENTAL RESIN DESIGNS DISCLAIMS LIABILITY FOR ANY

INFORMATION INCIDENTAL OR CONSEQUENTIAL DAMAGES.
To support customers in their product safety needs,
Resin Designs has an extensive Product Stewardship
organization and a team of Product Safety and Regulatory
Compliance (PS&RC) specialists available in each area.

For further information, please see our website,

www.resindesigns.com, or consult your local Resin Designs
representative.

Resin Designs is a registered trademark of Resin Designs.

All other trademarks or brand names are the property of their respective owners.
©2014 Resin Designs. All rights reserved.