Bulb Seal Molding Using Joinable Legs to Cut Manufacturing Cost

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Solution Overview

Problem

Current methods for manufacturing bulb seals, such as extruded hollow profile gaskets, require specialized equipment and are costly, while pour-in-place gaskets offer low compression forces and specific design requirements, necessitating a more efficient and cost-effective manufacturing approach.

Innovation Solution

The method involves molding a material into an unclosed seal with a first leg and a second leg connected via a connecting portion, which are then brought together to form a bulb seal, allowing for the use of injection or compression molding and avoiding the need for expensive extrusion equipment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Force

If extruded hollow profile gaskets are used, then compression force and space effectiveness are improved, but manufacturing cost increases

Engineering Contradiction:

Improvecompression forceVSAvoidmanufacturing cost

Core Design Contradiction:

ForceVSEase of manufacture

Solution Approach 1:

The bulb seal is divided into two separate legs (first leg and second leg) that are molded independently and then joined together. This segmentation allows the use of standard injection or compression molding equipment rather than requiring specialized extrusion equipment, thereby reducing manufacturing cost while maintaining the compression force characteristics of traditional bulb seals.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The seal is preliminarily formed as an unclosed configuration with spaced distal ends during the molding process. This preliminary action enables the use of conventional molding equipment to create a structure that will later be closed by joining the legs, avoiding the need for expensive extrusion equipment while achieving the desired compression force.

Inventive Principle:

Principle #10Preliminary action

2Device complexity

If pour-in-place foam gaskets are used, then manufacturing complexity is reduced, but compression force decreases

Engineering Contradiction:

Improvemanufacturing complexityVSAvoidcompression force

Core Design Contradiction:

Device complexityVSForce

Solution Approach 1:

The seal is segmented into two legs that are molded separately and then joined. This approach maintains manufacturing simplicity comparable to pour-in-place methods while achieving the compression force characteristics of extruded seals through the final closed configuration.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The seal is formed as a composite structure with two joined legs, combining the manufacturing simplicity of molded parts with the compression force characteristics of traditional bulb seals. The joining of the legs creates the closed configuration necessary for effective sealing and compression.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS20240328511A1Bulb seals and methods of manufacturing the same

Publication Date: 2024.10.03 CORNING RES & DEV CORP

AI summary

A method for manufacturing a seal comprises molding a material into an unclosed seal, the unclosed seal comprising a first leg and a second leg connected via a connecting portion, wherein a distal end of each of the first leg and the second leg are spaced from one another; and removing the unclosed seal from the mold, wherein the first leg and the second leg are configured to be connected to form a bulb seal.