Two-Layer Annular Seal Material for Visible Core Protrusion
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Solution Overview
Problem
Existing methods for manufacturing annular seal materials with a two-layer structure face challenges such as core protrusion at seams and parting lines, material breakage during inflation, complex and costly processes, and difficulty in confirming core protrusion due to similar material colors.
Innovation Solution
The development of an annular seal material with a core and outer layer made from crosslinked products of different crosslinkable rubber compositions, where the core and outer layer have distinct colors after hot press molding or secondary crosslinking, facilitating easy recognition of core protrusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different materials are used for core and outer layer, then material functionality is improved, but protrusion of core from outer layer at seam and parting line cannot be easily confirmed
Solution Approach 1:
The patent applies color differentiation between core and outer layer materials to enable visual detection of protrusion. The outer layer is formulated with a color different from the core material, allowing operators to easily identify any core protrusion at seams and parting lines during inspection. This resolves the detection difficulty while maintaining the functional benefits of using different materials for core and outer layer.
2Manufacturing precision
If outer layer portion is inflated during molding, then material coverage is improved, but outer layer portion material may break
Solution Approach 1:
The patent controls the inflation parameters during molding to prevent outer layer breakage. By optimizing the inflation pressure and timing, the outer layer is sufficiently expanded to achieve complete coverage without exceeding the material's strength limits. This resolves the contradiction between achieving good material coverage and preventing outer layer rupture during the molding process.
3Productivity
If manufacturing process is simplified, then productivity is improved, but process complexity and cost may increase
Solution Approach 1:
The patent combines multiple operations into a single integrated molding process. The core insertion, outer layer molding, and vulcanization steps are merged into one continuous operation, eliminating the need for separate handling and assembly steps. This simplification improves productivity while actually reducing overall process complexity by consolidating operations rather than adding separate processes.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution allows for easy identification of core protrusion at seams and parting lines, improving manufacturing productivity and reducing costs by simplifying the process and enhancing material integrity.
Implementation Method 1
the core and the outer layer comprises a crosslinked product of a crosslinkable rubber composition having a different color from each other either after hot press molding or after secondary crosslinking or both
Data Source
AI summary
The present invention relates to an annular seal material comprising a core and an outer layer covering a periphery of the core, wherein the core and the outer layer comprises a crosslinked product of a crosslinkable rubber composition having a different color from each other either after hot press molding or after secondary crosslinking or both. According to the present invention, provided are an annular seal material that can be mass-produced by using different materials for a core and an outer layer, respectively, and a method for producing the same.