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 978-683-9411.
Harder Faster
Less Flow
Harder Slower
Less Flow
Softer Faster
More Flow
Softer Slower
More Flow
Physical Properties
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Color, Part A Off White Off White Off White Off White
Viscosityat 25°C, cP, Part A, (RVT #5, 20 RPM) 7,000 4,500 3,500 4,500
Specific Gravityat 25°C, Part A 1.32 1.35 1.15 1.15
Densityat 25°C, lbs/gal, Part A 11.0 11.3 9.6 9.6
Color, Part B Black Black Black Black
Viscosityat 25°C, cP, Part B,
(RVT #5, 20 RPM)
11,000 11,000 7,000 7,000
Specific Gravityat 25°C, Part B 1.28 1.28 1.02 1.02
Densityat 25°C, lbs/gal, Part B 10.7 10.7 8.5 8.5
Color, Mix Grey / Black Grey / Black Grey / Black Grey / Black
Viscosityat 25°C, cP, Mix, (RVT #5, 20 RPM) 10,000 11,000 5,000 6,000
Specific Gravityat 25°C, Mix 1.29 1.31 1.07 1.07
Densityat 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 Timeat 25°C, Minutes, 100 grams 10 60 10 60
Shelf Life, See Product Information Bulletin (PIB) PIB PIB PIB PIB
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 CapacityCp, 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
seechart 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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seechart (-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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seechart

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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metallica 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_text 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 **
21
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Thermoplastics_text 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