Annular Seal Material Joining to Prevent Outer Layer Cracking
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Solution Overview
Problem
Existing manufacturing methods for annular seal materials face issues such as outer layer breaking, core protrusion, complex processes, and high costs, making mass production challenging.
Innovation Solution
A method involving preforming rope-like preforms with uncrosslinked core and outer layer, followed by two-stage hot pressing in molds with specific diameter ratios and temperatures to ensure seamless joint formation, using crosslinkable rubber compositions for core and outer layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the outer layer portion is inflated to form the annular seal, then the two-layer structure is formed, but the outer layer portion material may break
Solution Approach 1:
The outer layer portion is pre-formed into a string shape with appropriate dimensions before being inserted into the inner space of the tube-like outer layer portion. This preliminary preparation ensures that the material has the correct geometry and structural integrity before the inflation process, preventing breakage during forming.
2Ease of manufacture
If a composite structure material is cut and set in an O-ring mold, then the annular seal is formed, but the layer configuration at the seam does not have a two-layer structure
Solution Approach 1:
The inner layer portion is pre-formed into a string and inserted into the inner space of the tube-like outer layer portion before molding. This preliminary assembly ensures that the two-layer structure is established prior to the molding process, so that when the material is cut and joined at the seam, both layers are present and properly configured throughout the entire annular seal, including the seam area.
3Productivity
If the manufacturing process is simplified for mass production, then cost is reduced, but quality consistency may deteriorate
Solution Approach 1:
The inner layer portion is pre-formed into a string with precise dimensions and inserted into the outer layer portion before the molding process. This preliminary preparation step ensures that the two-layer structure is correctly established prior to molding, allowing for consistent quality across mass production while maintaining a relatively simple overall manufacturing process.
Solution Approach 2:
The manufacturing process is divided into distinct steps: pre-forming the inner layer into a string, inserting it into the outer layer portion, and then performing the molding operation. This segmentation allows each step to be optimized independently, ensuring quality consistency while maintaining productivity for mass production.
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
The method enables mass production of annular seal materials with suppressed outer layer cracking and core protrusion, ensuring consistent quality and cost-effectiveness.
Implementation Method 1
hot press molding to simultaneously vulcanize the inner and outer layers
Implementation Method 2
heating and pressurizing the resulting core material
Implementation Method 3
a preforming step of providing one or two or more rope-like preforms
Data Source
AI summary
The present invention relates to a method for manufacturing an annular seal material comprising a core and an outer layer covering a periphery of the core, comprising: a preforming step of providing one or two or more rope-like preforms comprising an uncrosslinked core made of a crosslinkable rubber composition for a core, and an uncrosslinked outer layer, made of a crosslinkable rubber composition for an outer layer, covering a periphery of the uncrosslinked core; a first hot pressing step of placing the rope-like preform in a first mold to hot press mold a portion other than end portions of the rope-like preform; and a second hot pressing step of contacting two end portions of the rope-like preform with each other and placing the same in a second mold to carry out hot press molding, in presented order.