Customized sealing solutions for EV charging stations

 

We carry out developments individually for your specific requirements

The 2-component reference material FERMAPOR K31-A-6060-4-B and B-60-AD (B component) presented here in medium-high viscosity is suitable for polyurethane foam gaskets on the mostly flat or three-dimensional application surfaces of the service panel of EV charging stations and has already been tried and tested by leading manufacturers. Thanks to the mixed-cell foam structure, the closing forces when installing the polyurethane foam gasket are low. It compensates for component tolerances during sealing.

Alternatively, we offer the thixotropic 2-component silicone sealing foam FERMASIL-A-93-1-VP3-GREY and B-93-VP1 (B component) for sealing EV charging stations.

Upon request, we can also customize our material systems to meet your component requirements and specifications. Influencing factors are, for example, the pot life before foaming starts and the curing time, as well as the viscosity, hardness and adhesion properties.

Sealing the service panel with these soft-elastic foam gaskets prevents moisture, dust or other foreign bodies from penetrating into the interior of the charging station and thereby avoids, among other things, the risk of possible corrosion of the electronics and electrical connections.

Protecting Electronics in EV Charging Devices

As the global volume of electric vehicles continues to grow, the need for reliable chargers is paramount. So that the chargers also perform properly as expected, protection of the charging electronics from environmental influences must be ensured.

Watch the video to see how the sealing of the housing structure is applied with our polyurethane or silicone sealing foams, helping to keep out dust, moisture and corrosion. At the same time, access for maintenance is always possible. The good resetting ability of the foam seal allows repeated opening and re-closing of the housing panels while maintaining the sealing effect.

 

Bespoke sealing solution for EV charging stations

 

The contour-accurate, robot-controlled Formed-In-Place-Foam-Gasket (FIPFG) application process is crucial for the precise application of sealing foams to the usually flat or three-dimensional application surfaces of the EV charging station service panel. This is done very precisely, safely and efficiently with our fully automatic DM 502 mixing and dosing machine.

When the service panel is closed, the foam gasket is compressed evenly over the entire length of the component contour and, when built into the overall structure of the charging station, produces a high level of impermeability in accordance with IP ratings. Due to its excellent shape recovery characteristics, the mixed-cell foam structure of the polyurethane seal can still be compressed well even after years (tested according to DIN EN ISO 1856). It is therefore possible to repeatedly open and close the service panel of EV charging stations for maintenance purposes while maintaining the sealing effect of the foam gasket.

The reference material FERMAPOR K31-A-6060-4-B generally achieves excellent adhesion to powder coatings and plastic surfaces. In special cases, adhesion can be improved by flame or corona pretreatment and by primer or plasma application.

 

The different reaction phases of the sealing foam in the chronological sequence

 

Reference material

    FERMAPOR K31-A-6060-4-B   FERMASIL-B-93-1-VP3-GREY
    FERMAPOR K31-B-60-AD  FERMASIL-B-93-VP1
Mixing   4.8 : 1 1:1
Pot life time   26 sec. 40 sec.
Tack-free time   3.5 min. 8 min.

Viscosity of the A component

  60,000 mPas 110,000 mPas
Density of the foam   0.25 g/cm³ 0.36 g/cm³
Hardness (Shore 00)   56 62
Temperature resistance   from -40 to + 80 °C from -60 to +180 °C
Pretreatment   Primer P23 (solvent based)
or P13 (water based)

Primer P8 or TEROSON SB450

In addition to the reference products, we develop material systems according to your individual requirements. Influencing factors include pot life until start of foaming, curing time, and the viscosity, hardness and adhesion properties.

 

Repeated opening and re-closing of the service panels for maintenance purposes, while maintaining consistent sealing effect

FERMAPOR K31 polyurethane foam gasket compensates for component tolerances during sealing and has a very good resetting ability of the seal foam structure.

This allows repeated opening and re-closing of the service panels for maintenance purposes, while maintaining a consistent sealing effect of the foam gasket.

It exhibits excellent long-term behavior even after years of continuous use and has good temperature resistance within a range of -40 to +80 °C.

The video shows the polyurethane foam seal FERMAPOR K31 in cross section - first in the uncompressed state, then 50% compressed, so that the sealing function of the seal is given.

The video shows the silicone foam seal FERMASIL in a cross section in a groove - first in the uncompressed state, then about 30% compressed, so that the sealing function of the seal is given.

Cross-section of a polyurethane foam bead – unpressed (without groove)

Silicone foam bead unpressed in the groove

 

Cross-section of a polyurethane foam bead with approx. 50 % compression

Silicone foam bead in the groove with approx. 30 % compression

 

 


Mixing and dosing system with 3-axis linear robot and shuttle table for sealing service panels of EV charging stations

 

 

Flexible and fully automatic – fully in line with your requirements

With the reference configuration shown here for sealing service panels of EV charging stations, we offer a perfectly coordinated system solution: a sealing foam that meets your requirements and a dosing system for high-precision and fully automatic material application controlled by contour robots. The configuration consists of the DM 502 mixing and dosing system with the MK 825 PRO precision mixing head and a 3-axis linear robot and shuttle table.

The two WT 1-LEVEL shuttle table plates allow parts to be picked up and machined in continuous shuttle mode, operating in a single plane.

Alternatively, we can offer the WT 2-LEVEL shuttle table with pick-up plates operating in shuttle mode, one above the other in two planes.

The highly efficient LR-HE plus 3-axis linear robot or, alternatively, the highly dynamic LR-HD ensures contour-precise guidance of the mixing head above the service panel. The sealing foam is fully automatically applied to the pre-programmed contour of the service panel with high dosing accuracy. After the dosing cycle, the coupling point of the foam gasket closes seamlessly and is therefore almost invisible. The applied material foams, expanding to several times its original volume, and forms an elastic soft foam gasket with the desired foam hardness at room temperature.

Our mixing and dosing machines can be operated easily and intuitively without requiring much training. Thanks to the automatic logging of dosing program data, all process data can be traced and evaluated by the machine operator via the CONTROL 2 operating panel while production is running.

In all solutions, our main focus is on extremely reliable plant engineering, minimized maintenance times and consistent dosing quality. As process experts, we support you with tailored advice for the automation of your manufacturing processes.

Even with short cycle times and large unit numbers, the material application process is carried out in the FIPFG (Formed-In-Place-Foam-Gasket) process with high dosing and repeat accuracy. As a result, when you install the service panel in the overall structure of your EV charging station, you get a foam gasket with consistently high quality and impermeability.