Tough-Seal Performs
Tough-Seal is the KEY material for the electronic encapsulation of sensitive electrical components requiring premium thermal cycling performance, excellent thermal shock resistance, and outstanding environmental and corrosion protection.
- Tough-Seal bonds exceptionally well to the walls of most plastic and metallic housings, frames and shells and stays in place without pull back during environmental exposure.
- Tough-Seal has specific and aggressive aluminium adhesion. Specifying engineers love Tough-Seal on aluminum housings when standard potting compounds crack, pull away, or disbond.
- For connectors, Tough-Seal adheres and seals to wire insulation and metal contacts and receptacles.
- It is soft enough to deliver a resilient and durable potting but firm enough to lock down receptacles so they are not prone to push back upon plug insertion.
- Tough-Seal is also now available in a higher viscosity formulation for glob-top encapsulating, allowing for localized potting and protection of vulnerable microelectronic components from environmental, mechanical & electrical damage.
Tough-Seal Superiority
Tough-Seal provides a unique combination of KEY properties not commonly found in just one potting compound.
If you use urethanes, Tough-Seal can extend your service temperature with an isocyanate-free solution that is not moisture sensitive.
If you use silicones, Tough-Seal offers a cost effective, non-silicone option with a friendly ratio and faster cure.
If you use epoxy, which is hard and rigid, Tough-Seal is an upgraded technology with exceptional flexibility that can withstand a wide range of service temperatures. With minimal exotherm, low shrinkage, and minimal expansion and contraction with temperature changes, Tough-Seal delivers low embedment stress, and outstanding thermal cycling performance.
Is Tough-Seal Right for Your Application?
Call Key Polymer now to find out, or order a kit & see for yourself.
Tough-Seal Properties
The physical, electrical, thermal and mechanical properties of all the Tough-Seal formulation can be compare below. These values are typical measurements and are provided as guide for specifying engineers. These values are not intended to be specifications.
Would you prefer to discuss your application with Tough-Seal Technical Service? Email our team or call (888) KEY-POLY.
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Harder Faster Less Flow
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Harder Slower Less Flow
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Softer Faster More Flow
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Softer Slower More Flow
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| Physical Properties |
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| Color, Part A | Off White | Off White | Off White | Off White | |
| Viscosity at 25°C, cP, Part A, (RVT #5, 20 RPM) | 7,000 | 4,500 | 3,500 | 4,500 | |
| Specific Gravity at 25°C, Part A | 1.32 | 1.35 | 1.15 | 1.15 | |
| Density at 25°C, lbs/gal, Part A | 11.0 | 11.3 | 9.6 | 9.6 | |
| Color, Part B | Black | Black | Black | Black | |
| Viscosity at 25°C, cP, Part B, (RVT #5, 20 RPM) | 11,000 | 11,000 | 7,000 | 7,000 | |
| Specific Gravity at 25°C, Part B | 1.28 | 1.28 | 1.02 | 1.02 | |
| Density at 25°C, lbs/gal, Part B | 10.7 | 10.7 | 8.5 | 8.5 | |
| Color, Mix | Grey / Black | Grey / Black | Grey / Black | Grey / Black | |
| Viscosity at 25°C, cP, Mix, (RVT #5, 20 RPM) | 10,000 | 11,000 | 5,000 | 6,000 | |
| Specific Gravity at 25°C, Mix | 1.29 | 1.31 | 1.07 | 1.07 | |
| Density at 25°C, lbs/gal, Mix | 10.8 | 10.9 | 8.9 | 8.9 | |
| Mix Ratio by Volume | 1A to 2B | 1A to 2B | 1A to 2B | 1A to 2B | |
| Mix Ratio by Weight | 51A to 100B | 53A to 100B | 57A to 100B | 57A to 100B | |
| Gel Time at 25°C, Minutes, 100 grams | 10 | 60 | 10 | 60 | |
| Shelf Life, Ambient, Part A Bulk (15°C to 35°C) | 3 Months | 12 Months | 3 Months | 12 Months | |
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Shelf Life, Ambient, Part B Bulk (15°C to 35°C) |
12 Months | 12 Months | 12 Months | 12 Months | |
| Shelf Life, Cold, Part A Bulk (-18°C to 3°C) | 12 Months | 12 Months | 12 Months | 12 Months | |
| Shelf Life, Cold, Part B Bulk (-18°C to 3°C) | 12 Months | 12 Months | 12 Months | 12 Months | |
| Electrical & Thermal Properties |
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| Dielectric Strength, 25°C, Volts/mil | 350 | 350 | 325 | 350 | |
| Volume Resistivity, 25°C, Ohm-cm x (10)12 | 1.20 | 3.75 | 2.10 | 1.75 | |
| Dielectric Constant, 25°C - 1 MHz | 5.00 | 5.00 | 4.75 | 4.85 | |
| Dielectric Constant, 25°C - 1 kHz | 5.50 | 5.45 | 5.20 | 5.25 | |
| Dielectric Constant, 25°C - 60 Hz | 5.75 | 5.85 | 5.35 | 5.45 | |
| Dissipation Factor, 25°C - 1 MHz | 0.026 | 0.021 | 0.024 | 0.025 | |
| Dissipation Factor, 25°C - 1 kHz | 0.028 | 0.034 | 0.021 | 0.021 | |
| Dissipation Factor, 25°C - 60 Hz | 0.064 | 0.089 | 0.044 | 0.043 | |
| Heat Capacity Cp, 25°C, J/g°K | 1.37 | 1.42 | 1.75 | 1.80 | |
| Thermal Conductivity, 25°C, W/m°K | 0.26 | 0.29 | 0.18 | 0.20 | |
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Coefficient of Thermal Expansion, ppm/°C | ||||
| (-) 65°C to 75°C | 135 | 145 | 168 | 200 | |
| 75°C to 100°C | 0 | 0 | 168 | 200 | |
| 100°C to 150°C | 75 | 155 | 168 | 200 | |
| Coefficient of Thermal Expansion, ppm/°F | |||||
| (-) 85°F to 167°F | 75 | 81 | 93 | 111 | |
| 167°F to 212°F | 0 | 0 | 93 | 111 | |
| 212°F to 302°F | 42 | 86 | 93 | 111 | |
| Hardness vs Temperature |
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(-75°C / -103°F) | 88 A | 91 A | 87 A | 84 A |
| (-25°C / -13°F) | 75 A | 78 A | 50 A | 48 A | |
| 5°C / 41°F | 69 A | 70 A | 44 A | 43 A | |
| 25°C / 77°F | 64 A | 68 A | 37 A | 40 A | |
| 50°C / 122°F | 62 A | 66 A | 37 A | 41 A | |
| 66°C / 150°F | 61 A | 69 A | 37 A | 42 A | |
| 80°C / 176°F | 62 A | 68 A | 37 A | 42 A | |
| 100°C / 212°F | 57 A | 64 A | 37 A | 42 A | |
| 120°C / 248°F | 51 A | 54 A | 35 A | 41 A | |
| 150°C / 302°F | 47 A | 53 A | 33 A | 39 A | |
| Hardness vs Ambient Cure Time |
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1 hour | 15 A | 0 A | 4 A | 0 A |
| 2 hours | 26 A | 10 A | 6 A | 0 A | |
| 4 hours | 31 A | 17 A | 11 A | 0 A | |
| 8 hours | 35 A | 30 A | 14 A | 0 A | |
| 12 hours | 35 A | 35 A | 14 A | 0 A | |
| 1 day | 39 A | 48 A | 16 A | 9 A | |
| 2 day | 46 A | 56 A | 19 A | 23 A | |
| 3 days | 52 A | 61 A | 22 A | 28 A | |
| 4 days | 57 A | 65 A | 23 A | 31 A | |
| 1 week | 60 A | 65 A | 30 A | 35 A | |
| 1 month | 68 A | 71 A | 41 A | 43 A | |
| Mechanical Properties |
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| Tensile Strength per ASTM D638, 25°C, PSI | 450 | 550 | 800 | 850 | |
| Elongation per ASTM D638, Type I, 0.125 in, 25°C | 225% | 250% | 400% | 450% | |
| Co=Cohesive Ad=Adhesive | |||||
| Tensile Lap Shear Strength per ASTM D1002, 25°C, psi ** |
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Aluminum Bare | 540 Co | 740 Co | 470 Co | 480 Co |
| Steel Bare | 530 Ad | 480 Ad | 260 Ad | 200 Ad | |
| Steel Ground | 480 Co | 600 Co | 280 Ad | 200 Ad | |
| Primed Steel | 530 Co | 560 Co | 150 Ad | 200 Ad | |
| Galvanized Steel | 560 Co | 700 Co | 260 Ad | 200 Ad | |
| Tin Plated Steel | 470 Co | 600 Co | 250 Co | 200 Co | |
| Chrome Plated Steel | 560 Co | 490 Co | 250 Co | 200 Co | |
| Tensile Lap Shear Strength per ASTM D3163, 25°C, psi ** |
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FRP - Polyester Fiberglass | 540 Co | 460 Co | 180 Ad | 210 Ad |
| Garolite G-9 Melamine/Glass | 530 Co | 620 Co | 130 Ad | 220 Ad | |
| Garolite G-10 Epoxy/Glass | 550 Co | 690 Co | 130 Ad | 360 Ad | |
| Garolite XX Phenolic/Paper | 570 Co | 520 Co | 190 Ad | 160 Ad | |
| Tensile Lap Shear Strength per ASTM D3163, 25°C, psi ** |
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Acrylic | 560 Co | 620 Co | 110 Ad | 300 Ad |
| Acrylic/PVC | 430 Co | 600 Co | 120 Ad | 250 Ad | |
| PVC - Polyvinyl Chloride | 530 Co | 570 Co | 150 Ad | 250 Ad | |
| CPVC - Chlorinated PVC | 660 Co | 670 Co | 170 Ad | 280 Ad | |
| ABS - Acylonitrile Butadiene Styrene | 500 Co | 580 Co | 120 Ad | 180 Ad | |
| PETG - Polyethylene Terephthalate | 610 Co | 610 Co | 100 Ad | 220 Ad | |
| Lexan - Polycarbonate | 520 Co | 630 Co | 90 Ad | 210 Ad | |
| Nylon 6/6 - Polyamide | 520 Co | 620 Co | 160 Ad | 260 Ad | |
| Polypropylene | 50 Ad | 30 Ad | 40 Ad | 40 Ad | |
| Polyethylene LDPE | 20 Ad | 0 Ad | 10 Ad | 10 Ad | |
| Polyethylene HDPE | 40 Ad | 20 Ad | 40 Ad | 20 Ad | |
| Teflon PTFE - Polytetrafluoroethylene | 40 Ad | 10 Ad | 20 Ad | 20 Ad | |
| Noryl - Polyphenylene Oxide/Polystyrene | 220 Ad | 200 Ad | 170 Ad | 150 Ad | |
| Ultem - Polyetherimide | 540 Co | 630 Co | 100 Ad | 170 Ad | |
| **20 mil Bondline, 1 in x 4 in Adherands, 1 in Overlap | |||||
