Bulb Seal Molding Using an Unclosed Preform Structure
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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 cost-effective and versatile 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 either compression or injection molding and avoiding the need for expensive extrusion equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If extruded hollow profile gaskets are used, then high compression forces and space effectiveness are achieved, but high manufacturing cost is incurred
Solution Approach 1:
The bulb seal is manufactured in two separate stages: first molding the unclosed seal with spaced distal ends, then later closing it by bringing the distal ends together. This segmentation allows use of standard injection molding equipment rather than specialized extrusion equipment, reducing manufacturing cost while maintaining compression capability
Solution Approach 2:
The unclosed seal is pre-formed with distal ends positioned to be brought together later, allowing the seal to be manufactured using conventional molding processes before final assembly. This preliminary formation enables cost-effective manufacturing while preserving the ability to generate high compression forces when closed
2Ease of manufacture
If pour-in-place foam gaskets are used, then low manufacturing cost is achieved, but low compression forces and specific design requirements are resulted
Solution Approach 1:
The invention uses injection molding or compression molding parameters to form the unclosed seal, then closes it by bringing distal ends together. This parameter change from open to closed configuration enables the seal to generate high compression forces comparable to extruded gaskets, overcoming the low compression force limitation of pour-in-place gaskets while maintaining cost-effectiveness
3Force
If extruded hollow profile gaskets are used, then high compression range is achieved, but expensive equipment and space are required
Solution Approach 1:
The manufacturing process is segmented into molding the unclosed seal separately from closing it. This allows use of standard, simpler injection or compression molding equipment rather than complex extrusion equipment, reducing device complexity while maintaining the ability to achieve high compression ranges when the seal is closed
4Ease of manufacture
If unclosed seal is molded and later closed, then manufacturing cost is reduced, but additional assembly step is required
Solution Approach 1:
The unclosed seal is pre-formed with distal ends positioned for later closing, allowing the main body to be manufactured efficiently using conventional molding. The closing operation can then be performed as a simple assembly step or integrated into the molding process, balancing cost reduction with maintained productivity
Data Source
Figure 1A
Figure 1B
Figure 2
AI summary
A method for manufacturing a seal comprises molding a material into an unclosed seal, the unclosed seal comprising a first leg (120) and a second leg (130) connected via a connecting portion (140), 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 (100).