Tag Archives: Dupont Kalrez

Kalrez® Composite Seals for Standard and Complex Geometries

For over 40 years, DuPont™ has been relentless in pursuing improvement in the manufacture of perfluoroelastomer (FFKM) parts. Elastomeric parts typically consist of three components: a polymer chain (the backbone of the elastomer), a crosslinking system (which links the polymer chains together and is the key to elasticity and sealing performance), and a filler system (used to enhance mechanical properties). Based on extensive experience, DuPont™ adjusts these components to optimize seal performance.


Composite Seals for Standard and Complex Geometries

kalrez spectrum o-ringsFor demanding standard and complex composite seal applications, Kalrez perfluoroelastomer parts are the elastomer of choice designed and molded to your specific requirements.  Kalrez composite seals offer unique one of a kind parts, in a wide variety of custom family shapes, standard geometry, and miscellaneous bonded parts, including small and large parts.  Whether you have a niche application or high volume runs, your sealing requirements can be met.  Kalrez composite seals are available in a variety of compounds depending on the thermal, chemical and plasma resistance required.

Kalrez® composite seal applications include; micro valves, micro-pumps, downhole oil and gas, semiconductor chip process equipment, ink jet, beverage dispensers, car wash pumps, printers, paint spray, refineries, CPI and more.

Types of Kalrez Shapes/Geometries

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Kalrez® Bonded Door Seals

picture of kalrez bonded door seals

Bonded door seals for gate valves and slit valve door seal applications provide improved sealing performance versus conventional O-rings by reducing particle generation, extending seal life, and minimizing replacement time during preventive maintenance.

DuPont Kalrez® bonded door seals are designed for easy installation and low particle generation. They combine a custom seal design and proprietary adhesion technology along with the excellent plasma resistance of Kalrez® perfluoroelastomer seal materials developed for semiconductor applications. The seal is held in a “fixed” position versus conventional O-rings, thereby eliminating “rolling/twisting” and abrasion during door actuation. In addition, the seal design has been optimized using finite element analysis (FEA) to minimize high concentrations of localized stresses. As a result, both particle generation and sealing performance are significantly improved versus conventional O-rings.

Typical Applications

Bonded door seals replace O-ring seals currently used in gate valve, and slit valve dovetail grooves in particle sensitive semiconductor etch, ash, strip and/or deposition processes.

Lower Particle Generation and Extended Seal Life versus Conventional O-rings

  • Sealing element held in a “fixed” position, i.e., eliminates “rolling/twisting” in service
  • Design eliminates O-ring abrasion against edge of dovetail groove during actuation/compression
  • Kalrez® semicon product grades used to minimize particle generation in reactive plasmas
  • Kalrez® Ultrapure post-cleaning and packaging reduces unwanted contamination
  • Improved sealing performance—optimal design minimizes high concentrations of localized stresses

Less Replacement Time Versus O-ring Seals During Preventive Maintenance

  • Quick and easy assembly/disassembly to mounting hardware
  • Reduces installation problems commonly experienced with O-ring seals
  • Eliminates need to clean the seal gland during preventive maintenance
  • Barcode on packaging plus bonded door seal part number and Kalrez® product number engraved on back of commercially available bonded door seals enables traceability and identification providing assurance that it is a Kalrez® perfluoroelastomer part (FFKM).

Availability

DuPont Kalrez® bonded door seals are available for a number of valve types used in semiconductor OEM equipment platforms.  In addition, a custom Kalrez® bonded door seal can be developed for most gate valve and slit valve door applications if not currently available.  Kalrez® UltraPure post cleaning and packaging is standard for all bonded door seals.


The original article was featured on Dupont Kalrez® website and can be found here.

Gallagher Fluid Seals is an authorized Kalrez® distributor. For more information about Kalrez products or to obtain a quote, please contact Gallagher Fluid Seals today.

What Makes Kalrez® Different?

Oil and gas production and chemical manufacturing industries present sealing technologies with some of the harshest and most demanding operating environments.

Harsh and Demanding Operating Environments Require Chemically Resistant and Thermally Stable Seals

“We screen Kalrez against some of the most aggressive corrosive fluids,” says Dr Christopher Bish, Technical Fellow. “And in addition to the fluid testing, we did some compression set testing and stress relaxation testing at high temperatures. We now have one of the most chemically resistant and thermally stable compounds possible.”

We screen Kalrez against some of the most aggressive corrosive fluids

What really makes Kalrez sealing technology superior and more durable than competitors?

One of the things that sets Dupont Kalrez apart is their quality control system, which gives them the ability to track materials as they flow through the plant. Scanning the barcode on the part bag can pull up the entire production history of that part, including raw materials and process conditions.

Is Every Kalrez Seal Inspected?

Elastomer Seal: Perfluoroelastomer Parts

Dupont performs a 100% visual inspection. It’s one way to ensure the quality rate is high and the return rate is virtually non-existent.

Despite the foreseen images of clean rooms, manufacturing in the semiconductor industry can be a harsh environment and cost of o-ring and seal replacement is significant.

“Kalrez parts are used as sealing materials in semiconductor wafer processing equipment, where high temperatures, aggressive chemicals, and plasmas are used. The most important thing for Kalrez sealing prodcuts is that the materials are resisting those aggressive conditions and not degrading  or contaminating the chambers,” says  Dr. Shuhong Wang, Technical Fellow.

Chemical and Science That Makes Kalrez Better

The polymer chains are fully fluoronated, forming one of the most inert polymer structures possible. Other elastomers have weak points along the chain structure, which are vulnerable to chemical attack and thermal instability. This, in combination with the unique cross-link technologies, many of which are patented, provides optimum durability and protection.

Check out a tour of one of the Kalrez manufacturing plants and learn what makes it the best choice for your demanding applications.


The original video can be seen on the Dupont website.

For more information, or to find which compound is best for you, contact Gallagher Seals. We are an exclusive distributor of Kalrez® seals.

Pharmaceutical Seals for CIP and SIP

Clean in Place Service Benefits from Kalrez® O-rings

Hilge-Pumpen AG, Swiss subsidiary of Philipp-Hilge GmbH, Bodenheim, Germany, selected Kalrez® 6221 perfluoroelastomer parts to seal its Euro-Hygia®, Hygiana-HT and Contra pump series, to meet the stringent safety, cleanliness and  sterilization requirements demanded by the pharmaceutical, biotechnology and cosmetics industries.

Pharmaceutical Seals for CIP and SIP

The Challenge

Pumps used in pharmaceutical, biotechnological and sterile processes are subject to some of the highest standards and safety requirements worldwide. In addition to ease of operation they must also provide maximum biological safety without any unfavorable hydraulic characteristics that could adversely influence sensitive products.

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Kalrez® Seals for Semiconductor Processing

Purity is critical to high wafer yield, and Kalrez® seals are designed with properties that help reduce contamination from particulates, outgassing and extractables.

Semiconductor Processing Seals

Kalrez® Seals - Semiconductor ProcessingKalrez® seals for semiconductor processing are field-proven in the manufacture of semiconductor chips.

They can help extend planned maintenance intervals, and thereby lower long-term cost of ownership, in a wide range of semiconductor processes. In a number of fabrication customer evaluations, Kalrez®seals exhibited improved mechanical strength, lower particle generation and longer seal life versus competitive perfluoroelastomers, in both static and dynamic sealing applications.

Operational Improvements

Kalrez® seals can help improve semiconductor manufacturing in a range of wafer-fabricating operations, including:

  • Deposition
  • Etch
  • Ash/strip
  • Thermal
  • Wet

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Case Study: How DuPont Kalrez Seals Cut Costs

DuPont KalrezDuPont™ Kalrez® – Total Cost of Ownership Analysis

The drive to reduce costs and environmental concerns have caused many design and processing engineers to turn to perfluoroelastomer sealing parts as the most cost-effective sealing solutions.  The value-in-use of perfluoroelastomer can be proven in operating conditions where conventional elastomers fail.  Even under less arduous conditions, DuPont Kalrez perfluoroelastomer seals can be the best solution, as they can last significantly longer than conventional sealing solutions.

Economics depend on the total system cost

When considering the economics of elastomeric seals, it is vital to look beyond the total cost related to the sealing solution.  The total system cost in use is the sum of the cost of the O-ring seal plus the installation cost plus the downtime cost (including loss of productivity through leakage and clean-up costs).

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