Blue Solar PV Junction Box Gel Seal | Cost-Effective Standard Grade Two Component Tank Sealant Jelly Gel

Hong Ye HY-9405 is a two-component addition-cure medium-tack blue jelly gel formulated for instrument, meter and electronic encapsulation where balanced flow, waterproof protection and serviceability are all required.

Product Overview:

Hong Ye HY-9405 is a two-component addition-cure medium-tack blue jelly gel formulated for instrument, meter and electronic encapsulation where balanced flow, waterproof protection and serviceability are all required. With a penetration of 170 plus or minus 30 (0.1mm), HY-9405 is firm enough to hold components in place during thermal cycling yet soft enough to absorb vibration and relieve stress on delicate solder joints and ceramic capacitors. The 1:1 mix ratio, 1800 mPa.s viscosity and 4 to 6 hour room temperature cure make it equally suitable for manual bench work and automated dispensing in high-volume meter, sensor and automotive electronics manufacturing. As a cost-effective standard grade, this variant offers proven performance at a competitive price for high-volume production. It is specifically formulated for sealing solar PV junction boxes against rain, humidity and UV exposure, where decades of field experience have shown that the seal must remain soft, tacky and compliant through thousands of hours of thermal cycling, vibration and maintenance operations. Backed by Hong Ye's nearly 20 years of silicone manufacturing expertise and supplied to customers in over 60 countries, HY-9405 combines the performance of premium imported gels with the cost efficiency, short lead time and responsive technical support of a Chinese manufacturer. Whether you are sealing a single biosafety cabinet or outfitting a 100,000-square-meter semiconductor fab, HY-9405 delivers consistent batch-to-batch quality, comprehensive documentation and application engineering support from first sample through full production ramp.

Key Features:

• Soft jelly-like consistency with buttery skin feel, comparable to premium German Wacker gel

• Self-leveling after pouring, no vacuum degassing required, saving process time and equipment

• Compatible with automated meter-mix dispensing equipment for high-volume production lines

• Permanently tacky surface that self-heals after filter removal and reinsertion

• Low exothermic peak during cure, safe for heat-sensitive electronic components and thin films

• 1:1 mix ratio by weight, easy to meter with manual or automated dispensing equipment

• Anti-yellowing grade available for transparent products requiring long-term clarity

• Excellent electrical insulation with dielectric strength above 20 kV/mm

• RoHS and REACH compliant; food-contact and skin-safe formulations available on request

• Third-party test reports including RoHS, REACH, FDA and LFGB available on request

• Recommended model: HY-9405 - Blue medium tack tank sealant jelly gel

Technical Parameters:

Detailed Application Scenarios:

For solar PV junction boxes, outdoor LED modules and underwater lights, HY-9405 provides IP68-level sealing that remains repairable. Instead of a permanently hard Potting Compound that forces replacement of the entire assembly if a diode fails, HY-9405 can be cut and peeled back for component replacement, then topped up with fresh gel. This repairability is increasingly valued by solar O&M teams and LED rental companies. The gel also resists UV yellowing and hydrolysis, maintaining sealing integrity after 25-year accelerated weathering tests that simulate the service life of roofhigh solar modules.

In smart water, gas and electric meters deployed outdoors, HY-9405 protects the register chamber, PCB and communication module from humidity, condensation, dust and insect intrusion. The medium-viscosity gel flows around tiny pins, connectors and antenna traces without trapping air, and its medium tack holds the cover plate in place while still allowing field service. Meters potted with HY-9405 have passed IP67 immersion tests, 1000-hour salt spray tests and thermal cycling from -40C to 85C without electrical failure, making it a proven choice for utility metering projects in coastal, tropical and desert climates.

Application & Operating Instructions:

Step 1 Substrate preparation: Ensure PCBs, housings and cavities are clean, dry and free of flux residue. If condensation is visible, pre-bake at 60C for 30 minutes and allow to cool before potting.

Step 2 Component B preparation: Stir component B for 1 to 2 minutes before dispensing to homogenize color and catalyst.

Step 3 Weighing and mixing: Weigh A and B accurately at 1:1 by weight. Mix thoroughly for 3 minutes, scraping container walls. For automated dispensing, use a meter-mix machine with static mixer nozzle of at least 16 elements.

Step 4 Potting: Pour or dispense directly into the cavity. The medium viscosity flows around component leads, connector pins and heat sinks without trapping air. A 2 to 4mm gel layer is sufficient for IP67 protection; deeper fills may be applied in layers if needed.

Step 5 Curing: Room temperature cure in 4 to 6 hours at 25C. For mass production, heat-cure at 60C for 30 minutes for fast demold. Allow parts to cool to room temperature before electrical testing.

Step 6 Rework: If component replacement is needed, cut and peel away the cured gel with a plastic tool. Fresh gel bonds well to clean cured gel, so simply high up the repaired area.

Model Selection Guide:

The HY-94 series offers three standard grades to cover the full range of jelly gel applications, and custom formulations are available for volume orders:

HY-9400 (Blue, High Tack, Penetration 200): The softest and most aggressive grade, designed for HEPA/ULPA filter gel seals in cleanrooms, biosafety cabinets, pharmaceutical GMP facilities, hospital operating rooms, semiconductor fabs, lithium battery dry rooms and data centers. Choose this model when maximum self-healing and conformability to knife-edge channels are the high priority.

HY-9405 (Blue, Medium Tack, Penetration 170): The balanced all-rounder for instrument meter sealing, electronic encapsulation and outdoor waterproofing. Typical applications include smart water/gas/electric meters, automotive ECUs and sensors, solar PV junction boxes, LED modules, underwater lights and pressure sensors. Choose this model when you need a combination of flowability, structural support, vibration damping and repairability.

HY-9409 (Transparent, Low Tack, Penetration 150): The premium skin-contact grade for intimate apparel and medical products. Typical applications include silicone bra pads, push-up inserts, breast prostheses, nipple covers, bridal and swimwear gel pads, orthopedic insoles and surgical positioning pads. Choose this model when clarity, dry skin feel, anti-yellowing and body-safe materials are required.

If your project requires a different penetration, color, cure speed or special certification (FDA, LFGB, UL94), contact Hong Ye technical support for a custom formulation. Custom MOQ starts from 20kg and typical lead time is 7 to 10 working days.

Recommended Application: Solar PV Junction Box Gel Seal

Quality & Compliance:

Every batch of Hong Ye HY-94 series jelly gel is manufactured under ISO 9001 certified quality management and tested for viscosity, mix ratio, cure time, penetration, color and tack before release. A Certificate of Analysis (COA) is provided with every shipment. Standard grades are tested to RoHS 2.0 and REACH SVHC requirements. HY-9409 uses food-contact grade raw materials and can be supplied with FDA 21 CFR 177.2600 and LFGB Section 30/31 test reports on request. All products carry a 12 month shelf life from manufacture date when stored sealed below 25C. Hong Ye has supplied jelly gel to cleanroom contractors, meter manufacturers, intimate apparel brands and medical device OEMs in over 60 countries since 2005.

Packaging:

Standard packaging options include 1kg trial kits (500g A + 500g B), 5kg kits, 20kg pails, 25kg pails and 200kg drums. Components A and B are supplied in separate containers within each kit. Custom packaging and private labeling are available for orders above 200kg. All kits are clearly labeled with batch number, manufacture date, expiry date and safety information.

Competitive Advantages:

Hong Ye HY-9405 stands out in the global jelly gel market through a combination of formulation expertise, vertical integration and customer-focused service. Our in-house silicone polymer synthesis and compounding lines give us full control over raw material quality and batch consistency, while our 20,000-square-meter Shenzhen factory supports monthly output of over 500 tons of addition-cure silicone. This scale allows us to offer prices typically 30 to 50 percent lower than imported German Wacker and American Magna-Dyne gels without compromising on performance. We maintain local stocks of standard grades for 3 to 5 working day delivery, and our technical sales engineers are available for on-site pouring trials, gel channel design reviews and custom formulation projects. For OEM customers we provide private labeling, neutral packaging, COA documents in multiple languages and dedicated batch traceability, making it straightforward to integrate our gel into your supply chain whether you consume 20kg per month or 20 tons per quarter.

Ordering and Logistics:

To order HY-9405, contact Hong Ye sales with your required model, quantity, destination country and preferred courier. We accept T/T bank transfer, PayPal for sample orders, and Alibaba Trade Assurance for online orders. Standard packaging ships from stock within 3 to 5 working days after payment. We ship worldwide via DHL, FedEx, UPS and sea freight for bulk orders. Dangerous goods classification is not required for addition-cure silicone gel under most transport regulations, simplifying international shipping. All shipments include commercial invoice, packing list, COA and safety data sheet.

Technical Support and Customization:

Hong Ye operates a dedicated technical service team staffed by silicone chemists and application engineers with an average of more than 10 years of industry experience. We support customers throughout the entire product lifecycle: initial grade selection based on your drawings and service conditions, on-site or remote pouring trials, gel channel and mold design review, cure profile optimization, failure analysis and ongoing quality improvement. For customers with special requirements, our R&D center can develop custom formulations with adjusted penetration (120 to 260 in 0.1mm units), custom Pantone colors, accelerated or delayed cure profiles, flame retardant grades meeting UL94 V-0, thermal conductive grades, food-contact FDA and LFGB certified grades, and medical grade formulations with biocompatibility testing. Custom development typically takes 7 to 14 working days from confirmed requirements to shipped samples, and the custom formula becomes your exclusive formulation for ongoing orders. We also provide gel consumption calculation, cost-per-seal analysis and comparison testing against your current sealant to help you make data-driven sourcing decisions.

Precautions:

Use polyethylene, nylon or nitrile gloves; never use natural rubber latex gloves. Avoid contact with sulfur-containing materials, amines, phosphorus compounds, tin-cured silicone and PVC, as these inhibit the platinum catalyst and prevent cure. Mix A and B at exactly 1:1 ratio by weight using a calibrated scale. Stir thoroughly for 3-5 minutes, scraping container walls and bottom. Do not exceed 100°C during heat curing. Ensure good ventilation during operation.

Storage:

Store sealed containers in a dry, ventilated area below 25°C, away from direct sunlight, sulfur-containing materials, amines, food and strong chemicals. Shelf life is 12 months from manufacture date. Reseal unused material immediately after dispensing. Refrigerated storage at 5-15°C can extend shelf life; allow material to return to room temperature before opening to prevent condensation.

FAQ:

Q: What is the shelf life and how should the gel be stored?

A: Sealed containers have a 12 month shelf life when stored below 25C in a dry, ventilated area away from direct sunlight. Reseal unused material immediately after dispensing. Keep components A and B separate. Do not store near sulfur-containing materials, amines, food or strong chemicals. Refrigerated storage at 5 to 15C can extend shelf life, but allow the material to return to room temperature before opening to avoid condensation.

Q: Will the gel self-heal after a HEPA filter is removed and reinserted?

A: Yes. The cured gel remains permanently tacky and soft. When the knife edge is lifted, the gel temporarily separates; when reinserted, it flows back around the blade within minutes, restoring the airtight seal. This self-healing property is one of the key advantages over compressed gaskets and is especially valuable during periodic filter replacement in cleanrooms and biosafety cabinets.

Q: What is the mixing ratio and how accurate must it be?

A: All HY-94 series gels use a 1:1 mix ratio by weight. Accuracy should be within plus or minus 2 percent. Off-ratio mixing causes incomplete cure, soft spots or sticky surfaces. Always use a calibrated digital scale rather than estimating by eye or volume.

Q: How much gel do I need per HEPA filter or per product unit?

A: For a standard 610x610mm HEPA filter with a 15x25mm gel channel, approximately 200 to 350 grams of mixed gel is required per filter. A 20kg pail seals 60 to 100 filters. For bra pads, a typical push-up insert uses 30 to 80 grams per pair. We provide a free gel consumption calculator based on your channel dimensions or product drawings.

Q: How long does the gel take to cure and can I speed it up?

A: At 25C the gel reaches touch-dry in 4 to 6 hours and full properties after 24 hours. For mass production, heat-curing at 60 to 80C reduces demolding time to 30 to 60 minutes. Do not exceed 100C as it may cause discoloration or surface defects. Low temperatures below 15C will significantly slow the cure.