Perfection every time

FIPFG

Seals that are perfectly connected to the workpiece, highly elastic, precisely sized and economical: KÖPP has been supplying FIPFG sealing systems for over 15 years. In the FIPFG process (formed-in-place foam gasket), a dual-component sealing system still in its liquid pre-reaction form is applied in-situ, directly to the component in the precise contour using a robot.

The technology offers a range of options that is as wide as the sealing requirements of our customers. This means on-site technical advice is indispensable. Thanks to our experience and technical expertise, we always find the perfect solution with our customers.

Areas of application

 
 
 
 
Foam bead
4-component foam

Technology that adapts to your situation

KÖPP uses its unique range of dosing machine tools to apply foamed seals (FIPFG) at two locations in Germany. These systems are also used for gluing and potting. The key factors are your requirements and the technical specifications of your application. The density, reactivity and above all fluidity of the components are specifically determined to meet your needs. In simpler, two-dimensional notch applications, low-viscosity systems are used, for example. In applications that are three-dimensional or in a plane (e.g. in a switch cabinet or inverter), high-viscosity systems or thixotropic systems are used.

2-component systems

Application of foamed and elastomer seals, adhesives and potting materials

4-component systems

Application of “core-shell seals”

Notch shapes

You can find all the FIPFG design guidelines at our Service Centre.

Advantages of this technology

  • Virtually no joint or adhesive point, the seal is “endless”
  • Captive, firmly connected to the component
  • Flexible, quick adaptation with experienced machine operators
  • Economical, as the seal and component do not have to be manually matched
  • 3D-seals are possible thanks to thixotropic systems
  • Varied foam types optimised for applications
  • We make our own tools for precise inputs and exact dosing – perfectly reproducible

Materials

Polyurethane (PUR)

Polyurethane (PUR)

PUR solid rubber seals have a mixed-cell structure, which means they have very good resilience in FIPFG processes. They can withstand temperatures from -40°C to + 80°C, even 120°C for extreme applications.

The dual-component systems used at KÖPP are softener-free and have good chemical resistance. Formed-in-place PUR seals are commonly used for switch cabinets, lights and the automotive sector.

Stay flexible with outsourcing

An increasing number of customers use the outsourcing model to stay flexible. Thanks to our large storage and logistics capacities at two locations, an increasing number of mass manufacturers outsource their process responsibilities and entrust their workpieces to us – often several hundred thousand components per year.

Our customers also make the most of our expertise in the area of potting and gluing. A thixotropic seal can be applied immediately to a circuit board during the first step, which then prevents the potting from escaping (dam and fill method). We'll be glad advise you about your options.

FIPG workpieces
Enquiry/projection

Enquiry/projection

Development/technical specification

Development/technical specification

Sampling

Sampling

Assembly

Assembly

Release/mass production

Release/mass production

Logistics

Logistics

Technical data

Parameters 2-component PUR 4-component PUR
Number of components 2 4
Seal shape H/W Minimum 1x2 mm* Minimum 3x6 mm
Temperature resistance -40°C to +100°C (up to +160°C for short periods) -40°C to +100°C (up to +160°C for short periods)
Resistances Very good, but must be checked for individual cases Very good, must be checked for individual cases
Adhesion Very good, opt. surface activation Very good, opt. surface activation
Viscosity Thin to thixotropic Thixotropic
Compression set (24 h/50%/70°C) To less than 3% is possible **) <3%
Shore hardness 5 Shore 00 to 40 Shore A >35 Shore 00
Stress-strain compression (25% compression) 5 kPa to 200 kPa n/s
Tensile strength Up to 2 MPa [N/cm²] >800 kPa
Ultimate elongation up to 400%
Cellular structure Mixed-cell Mixed-cell with closed external skin (core-shell)
Density (g/m³) From 0.1 - 0.6 <0.4
UV-resistant*** Optional Optional
Colour**** Black, anthracite Black
Flame retardant, UL 94 On request On request
Approved for contact with foodstuffs Special types -
EMC, anti-static - On request
Water absorption From <3.5%, can be made hydrophobic <3%
Other Various UL 50 modes with microbicide sliding systems low-fogging systems softener-free Skin thickness approx. 0.2 - 1 mm, good adhesion even on many metals, improved chemical resistance, Approved for contact with foodstuffs

* Height (H) / width (W) information for thixotropic applications (see design guidelines and notch applications)
** The compression set is very good, also because it is mixed-cell. However this is a function of the temperature, the type and duration of load, see DIN standards
*** Special types available; long-term behaviour should be checked for individual cases

Cutting-edge programming and control electronics for perfect dosing results 
Cutting-edge programming and control
electronics for perfect dosing results
FIP(F)G production 
FIP(F)G production
6-axis dosing system for complete sealing contours 
6-axis dosing system for complete
sealing contours