Sealing and Shielding

High performance QSFP-DD optical modules must use thermal interface materials to help dissipate heat efficiently and effectively to ensure the optimum operating performance, reliability and dependability of the high-speed transceiver.

The introduction of QSFP-DD, or Quad Small Form Factor Pluggable Double Density optical modules, have now doubled of the number of high-speed electrical interfaces that the module supports compared with a standard QSFP28 module.

Greater density, greater heat

QSFP-DD modules are the newest standard in high speed pluggable connectors, as they are the smallest form factor 400 G/s transceivers, offering the highest bandwidth density while leveraging the backward compatibility to lower-speed QSFP pluggable modules and cables. Highly integrated and advanced PAM-4 DSP chips, externally modulated laser (EML) diodes, and GaAs laser diodes enable the 400 G/s performance, yet these ICs come with significant thermal issues.

Power loads of up to 25W require significant considerations for heat dissipation, including the application of thermal interface materials.

The goal of a system thermal design is to remove the heat from the module case to ensure that the internal components in the module stay within operating temperature ranges to ensure optimal performance and reliability.

The role of thermal interface materials (TIMs)
Thermal interface materials such as thermally conductive gap filler pads, thermal greases, and dispensed thermal gels improve heat dissipation by filling minute air gaps and voids and by being dispensed or in contact with heat generating chipsets. Maximizing the contact area of the heatsink to the module lowers the thermal resistance and improves the system’s ability to cool the module.  Types of TIMs available

High power thermal gels, such as Parker Chomerics THERM-A-GAP GEL 75, with 7.5 W/m-K thermal conductivity, as well as high performance single component thermal greases such as THERM-A-GAP GEL 8010 3 W/m-K, are typically robotically dispensed for high volume applications such as optical modules.

Robotically dispensing thermal interface material can dramatically reduce costs, save valuable time, and greatly improve the overall performance of the QSFP-DD module. Thermal gap filler pads can be die cut into exact shapes to help dissipate heat from any heat generating component. Thermal gap filler pads provide a soft and effective method of heat dissipation as well as helping to reduce vibration stress for shock dampening. 

Need help deciding on a thermal interface material? Our recent blog Thermal Gels or Gap Filler Pads? Top 6 Things You Should Know can help!

A TIM for every design; yes, even yours

Whatever your design is, be it a stacked card cage, or belly-to-belly, the thermal interface between the optical cable connector module and the heatsink attached to the outer case/cage is important to your design.

With speeds of 400 G/s being introduced now and 800 G/s on the near horizon, you must also consider the thermal heat dissipation needs of not only the module itself, but the interface connection on the PCB, as well as at the rack unit or cabinet level. 

Cabinets featuring 40U to 46U racks require immense thermal heat dispersion featuring both active and passive cooling technologies. Higher data transfer speeds, low latency, and constant availability require more computing power, which in turn means higher power densities per rack.

No matter what your thermal interface material need, Parker Chomerics can help, download our Thermal Interface Materials for Electronics Cooling Guide now!

 

 

 

 

 

This blog post was contributed by Jarrod Cohen, marketing communications for Parker Chomerics

 

 

 

 

 

 

 

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New THERM-A-GAP GEL 75 Thermal Gel Offers High Thermal Conductivity and Reliability

We receive many requests regarding seal retention but why is it so important? There are 3 main reasons: ease of component assembly, serviceability, and transit issues. For example, seal retention is important when you have complex groove paths where your groove wanders around bolts or ports. It is also valuable in improving operator ergonomics by reducing installation strain or fatigue in high volume applications.  Additionally, seal retention improves serviceability by eliminating the need for liquid sealants which can be difficult to clean. Last but not least, seal retention resolves transit issues by ensuring seals are retained from workstation to workstation or if components are assembled in different locations.

Parker offers an array of Press-in-Place (PIP) Seals to accommodate these application challenges. Additionally, each particular profile provides performance properties to address issues like larger tolerance stock, low seal load, and complex groove paths to name just a few. 

Press-In-Place Benefits

Parker’s Press-In-Place (PIP) seals are custom designed to fit into complex groove patterns without having to be stretched. These custom seals are designed to withstand a wide variety of environments, fluids, pressures and temperatures.

In comparable seal heights, a standard PIP groove is 60 percent narrower than traditional grooves. Seal retention is achieved by sidewall interference, requiring no adhesives. The PIP design also maintains high pressure differentials, provides lower seal load, optimizes material use and is easy to install.

Compared to dispensed Form-In-Place (FIP) seals, PIP seals have several advantages. For example, during maintenance, PIP seals can be easily and quickly changed out, where FIP removal often damages the groove. FIP seals also require a considerable investment in machines and fixtures while PIP seals deliver higher performance and robustness without expensive tooling or fixture costs. 

Parker offers a variety of PIP standardized profile options. These include:

• Molded Diamond—molded to the shape of the groove path using retention beads intermittently along the seal to keep it secure. This PIP seal can save space up to 60 percent versus traditional seals and allows a much smaller bend radius. The diamond seal can combine multiple parts into one and enables fast assembly. Applications include high volume automotive and low volume military programs.
• Hexapod—excellent for retention and lower pressure applications. It is also extruded and spliced which makes it a great choice for large enclosures. Applications include EV battery and heavy-duty engines.
• Keyhole—also extruded and spliced with reduces deflection and number of fasteners thanks to its low load. This PIP seal is also great for environmental sealing (little or no pressure) and larger tolerances, and is easy to install. Applications include plastic housings and stamped covers.
• Jigsaw—extruded and supplied in long lengths with no splicing required. The Jigsaw seal can be cut to size and requires no adhesive but does require a groove overlap. Applications may include multiple port sizes where just one part number can be used for the whole assembly, and in field installations where a pre-sliced or continuous part may be impossible to install.
• O-Ring—this seal is a good solution for retention and comes in three types: standard & custom sizes; extruded with spliced rings and cord stock; and custom molded plan view. Each type has its own benefits and limitations including cost effectiveness, bend radius, customized cross-sections and more.
• EZ-Lok—an axial seal designed for retention in dovetail grooves. the EZ-Lok seal is designed specifically to simplify and error-proof the installation process. In addition, this PIP seal minimizes seal wear on groove corners and removes the parting line from the sealing surface. It is currently used in the semiconductor market and is recommended when seal installation and performance are critical. 
• Hollow O-Ring—extruded, spliced and low load which allows for a reduction in fasteners or clamps. They are easily customizable and are slightly oversized compared to the groove. However, they will not overfill the groove like a standard O-Ring. Like other hollow profiles, the Hollow O-Ring is not suitable for high pressure applications.
• Bulb—come in standard and custom profiles and are highly compliant to variation, i.e., your components to flex, run out, etc. If you have a groove that is already machined or spec’d in and you need a seal to fit, a custom bulb seal may be your best option.

Other retention options include: Friction Fit Hollow O; Friction Fit Hollow Profile; PSA on Profile; Dart Profile in Custom Groove; Dart Profile in FF Groove; Hollow Profile Mechanically Fastened; PSA on Hollow D; and Hollow Profile Pressed into Metal Track.

A full summary of our PIP options with performance properties and our recommendations are provided in our Press-In-Place (PIP) Sealing webinar below. For help in determining the right solution for your application, please contact our O-Ring & Engineered Seals design team at OESmailbox@parker.com or 1-859-335-5101.

 

 

   

 

 

 

 

This blog was contributed by Samantha J. Sexton, marketing communications manager, Parker O-Ring & Engineered Seals Division.

 

Press-in-Place Seals for Axial Sealing Applications

Press-in-Place Seals Solve Problems for Automotive Applications

Innovative Solutions Improving Seal Retention

Challenges abound for oil and gas companies during drilling and well completion operations. Drilling mud and frac fluids are some of the harshest and most destructive media to be sealed. It takes tough, rugged sealing components to last long run-time hours and continuously move high volumes of abrasive frac fluid that cause wear and tear on parts. And thermoplastic polyurethanes are raising the bar for performance expectations and proving out as preferred sealing materials.

Polyurethane has been an industry standard for dynamic sealing in hydraulic applications for more than 30 years. But polyurethane materials are not all formulated from the same hard- and soft-segment chemistry. The specific diisocyanate and chain extenders used in the synthesis of a polyurethane affect its physical and mechanical properties. When looking to achieve the best performance with mud and frac pumps, Parker’s Resilon® polyurethane is recommended. Our proprietary PPDI (p-phenylene diisocyanate) TPU formulation is specifically suited for injection molding of both large and small articles while retaining superior high-temperature performance.

The characteristics common to Resilon formulations make this PPDI class of material a leading choice for high pressure, dynamic sealing applications. These characteristics include exceptional:

• Wear resistance
• Thermal stability
• Hydrolytic stability
• High bond strength
• Compression set resistance
• Resiliency

 

Where to Use Resilon

 

Resilon polyurethane can be used with high effectiveness in many areas on mud and fracking pumps. The advantages are evident in each area.

Pony Rod Seals.  Eliminate hydraulic fluid leakage and simplify installation by replacing standard two-piece seals with the single-piece design made from Resilon 4300. With its high contact force sealing lip design, coupled with compression-set resistant Resilon seal material, this patent-protected pony rod seal design retains lubricating oil in the power end, eliminating necessity of shut down to replenish lost hydraulic fluid. When maintenance and change over is called for, pony rod seal installation is much simpler. The integrated, single component oil seal/rod wiper can be secured via press fit so there’s no need for snap rings or retaining plates. 

 

 

"Our sales team members receive inquiries from well completion operators who are frustrated when they are interrupted and have to shut down to replenish gallons of hydraulic fluid lost from leaking seals. These operators and their service technicians who are in the field doing the change-overs make it known they 'want the the tan colored pony rod seal,' referring to Parker's recognizable tan-colored Resilon 4300 formulation. Some operators are so pleased with the performance of the Parker pony rod seal they are demanding that the mud pump manufacturers install it as a condition to deploy their pumps on the job site."

Dana Severson, oil and gas market sales manager for Parker's Engineered Materials Group

 

Suction and Discharge Cover Seals. Our HGP Profile suction and discharge cover seals provide four times the reliable service life compared to traditional elastomer D-rings. Owing to its combination of unique geometry and Resilon 4300 polyurethane material, the HGP Profile resists wear due to the abrasive fluid proppant, high pressure and vibrating motion generated by high frequency pulsating pressurization. The tough, rugged material improves sealing reliability and minimizes degradation of fluid end mating hardware.

Fluid End Valve Seats. Valves take a beating from repeated cycling in highly abrasive drilling fluids and aggressive fracking fluids. But valves made with our unique geometry and Resilon polyurethane have shown to extend valve life by over 50 percent. Resilon valves reduce material failure caused by hysteresis and the optimized geometry increases service life and reliability of the valve seal. These can be formulated in both bonded and snap-in configurations.

Mud Pistons. Our design expertise in piston sealing applications has resulted in piston cups that outlast the competition, reducing costly downtime and eliminating leaks. Resilon polyurethane piston seals are long wearing and outperform traditional urethanes in hot water. Enhanced resilience/rebound characteristics allow the sealing lips of the mud piston to conform to the seal interface – maintaining consistent critical sealing lip contact under rapid cycling conditions, plus reduce frictional heating. In addition, Resilon formulations are compatible with oil and water-base drilling muds. 

Well Service Packings. For positive displacement pumps, the materials used in our well service and vee-ring packings have exceptional compressive force resistance to manage side loading yet remain pliable enough for sealing. The material range includes Resilon polyurethanes to aramid fabric reinforced HNBR/FKM. Resilon is compatible with a wide range of hydraulic fracturing fluids.

 

Resilon® Material Formulations Help Overcome Oil & Gas Completion Challenges

 

With well conditions becoming increasingly challenging and taking a toll on equipment and expendables, you require sealing products that will enable you to achieve greater production efficiencies, improve performance and reduce down time. Whether you service frac pumps, run completion operations, or build frac pump equipment, Parker’s proprietary Resilon materials can improve your bottom line by:

• Reducing frequency of component replacement (MTTM)
• Reducing cost for maintenance since less maintenance and fewer replacement parts are needed
• Providing better compatibility in water application
• Ensuring rugged, resilient sealing force

Learn more about Resilon® and watch Parker’s video on temperature/pressure challenges and sealing requirements for Oil & Gas.

 

This blog post was contributed to by Shannon Johnson, marketing communications for Parker Engineered Polymer Systems Division.

 

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