As outlined in the whitepaper “Types of Hermetic Seals” by Douglas Electrical Components, hermetic sealing is essential for ensuring airtight closures in various applications, from aerospace to industrial electronics. Two of the most common sealing methods are glass-to-metal seals and epoxy-based seals, each offering distinct advantages depending on the application requirements.
A glass-to-metal seal is created by fusing borosilicate glass, metal housing, and electrical conductors through a controlled heating process. This results in a highly durable, corrosion-resistant, and reliable seal that can withstand extreme environments. Glass-to-metal seals are ideal for applications requiring high dielectric strength, long-term stability, and resistance to harsh chemicals or pressure variations.
Alternatively, hermetic epoxy sealing uses an epoxy resin to encapsulate electrical conductors, such as pins or stranded wires, within a metal housing. The epoxy undergoes a thermal curing process to create a seal. Epoxy seals allow for higher signal density, making them effective for applications where multiple conductors must pass through a small opening. Douglas Electrical Components uses a NASA-certified low-outgassing epoxy, ensuring minimal contamination in sensitive environments.
While glass-to-metal seals provide unmatched durability and resistance, epoxy seals offer greater flexibility in high-density applications. Choosing the right hermetic sealing method depends on factors such as chemical compatibility, outgassing requirements, environmental exposure, and signal density needs.
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Article with all rights reserved, courtesy of Douglas Electrical Components.