Foam Gasketing Forming Machines

FOAM GASKET FORMING MACHINES

Our partner, Shanghai Kaiwei is a high-tech enterprise devoted to innovation and research and development with business activities covering many countries all over the world. They are renowned worldwide for their Form in place Foam Gasket ( FIPFG) machines, beading machines also known as PU foam sealing machines and also Injection Potting machines, Plate spraying cementing machines.

These machines are used as foam gaskets (Gasket forming machines) for various applications. Some of the applications are depicted below.

A form-in-place gasket is created by dispensing a liquid Polyurethane Sealing Foam gasket onto a metal or plastic part before assembly. Because it is dispensed as a PU liquid, it fits precisely to the part’s form, regardless of housing imperfections. This results in a reliable seal and durable finished product. FIP gaskets are dispensed using CNC machines with our Kaiwei machines.

The process is so precise that surfaces less than one millimeter wide can still receive PU FIP gasket application. Polyurethane FIP gaskets are a cost-effective, accurate, and easy sealant solution, particularly in cases where a very small, narrow, or higher IP or complex gasket is required.

PU FIP is most selected for the below applications

• EMI shielding for electronics
• Environmental sealing for dust or water protection
• Sealing for adhesive reasons to make assembly simpler

Some examples of specific industries and the FIP gasket applications they might require include:

• Electronics: electronic enclosures, GPS systems, satellite communication, semiconductors, lighting 
• Electrical Cabinets 
• Medical devices: ventilators, oxygenators, heart pumps, dialysis machines
• Defense and military: radar, missile guidance, GPS systems
• Communications: WiFi routers, cellular devices, cellphone stations
• Aerospace: drones, airplane seats, airport ground equipment, flight instrumentation
• Mass transportation: mechanical equipment, seating, accessory components

FIP gasketing provides a highly reliable seal that will stay resistant to freezing, water, heat, UV, corrosion, and more. Not only is the gasket durable, but it is flexible and can be used on even the most complex parts which with high standards.

Advantages of FIP Gaskets

Some of the most important advantages of using form-in-place gaskets are their adaptability across a wide variety of conditions and the ability to produce intricate details. It is possible to dispense large or small gaskets depending on to meet customer demands.

Another important benefit is the speed to install an FIP gasket. Once a FIP gasket is dispensed, there is no additional work to assemble the product which creates a turnkey solution that is ready for use.

Dispensing Technology

The FIP gasket dispensing process is straightforward. Most manufacturers use robotic gasket dispensing to apply the material to the housing across a specified dispense path. The primary steps to gasket dispensing include:

The PU liquid chemicals are inserted into the gasket dispensing machine

The machine dispenses the chemicals through a needle and applies a gasket bead to the housing, with the dispenser moving across a pre-specified path using a CNC machine on metals or plastics.

PU FIP gasket is kept for some time to form a 2:1 ratio

FIP gasket is resistant against heat, water, moisture, or UV light.

 Alternatives to FIP gaskets include the use of pre-cut custom gaskets, but to achieve a precise and cost-effective result, manufacturers rely on automated gasket dispensing technologies. Attempting to apply very small, narrow, or complex gaskets by hand significantly increases assembly cost and effort with a CNC gasketing machine.

FIP gasket dispensers may have the following features:

• CNC dispensing
  
• Material sensors
• Automatic rotation
• Vertical dispensing
• Needle tip calibration
• Dosing and mixing automation
• Automated head cleaning.

Dispensing or CNC Gasketing machines are perfect for handling critical electronic assembly while some others are better suited for simple, small-scale manufacturing companies like electrical cabinets or doors. Either way, these machines make Form-In-Place gasketing that much more delicate and accurate, resulting in products with high-quality protection. 

Adaptable to Multiple Surface Considerations

The Form-In-Place gasket process dispenses silicone directly onto metal or plastic surfaces. The process allows for changes in elevation, uneven surfaces and thin profiles. With gasket shelf probing and other sensing technology, Form-In-Place can be a perfect solution for less-than-perfect molded housings and as-cast metal shields. Probing the gasket shelf prior to dispensing can mean cost savings in the form of less machining and housing rejects.

Small Gasket Dimensions

A valuable benefit of Form-In-Place gaskets is its inherent ability to place the thinnest possible bead within the very smallest cross sections. This means Form-In-Place technology supports densely populated electronics packaging, especially when inter-compartmental clearance or isolation is necessary.

Automated Process

Form-In-Place gaskets utilize a robotic system which ensures repeatability and accuracy regardless of the size of your production run. This process allows the gasket path to conform to complex and intricate designs while maintaining tight tolerances.

In general form-in-place dispensing may be a good choice for the following situations:

• Small, complex, and intricate gaskets.
• EMI shielding for electronics.
• Environmental sealing for dust or water protection.
• Resistance to freezing, heat, UV, and corrosion.
• To achieve some standard for final product. 
• Fast assembly or short turnaround time requirements.
• Situations where installation of the gasket is very difficult or would be made easier if the gasket was adhered to the part surface.