Composite Seal Cutting with Segmented Punches to Prevent Substrate Warping
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Solution Overview
Problem
Current sealing devices, particularly those made of flexible elastomer materials, face challenges in automation due to their rigidity, which makes them difficult to fit into complex-shaped grooves, and existing methods for producing composite gaskets are either costly or result in warped products unsuitable for modern manufacturing tolerances.
Innovation Solution
A method involving the use of two opposed punches with aligned cutting edges that penetrate a rigid plate coated with resilient material, allowing for precise cutting without warping the substrate and achieving straight cut edges, enabling the production of stiff, shape-stable sealing devices that can be easily automated and mounted.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If flexible elastomer sealing devices are used, then they can deform to fit grooves, but they lack rigidity and are difficult to automate fitting
Solution Approach 1:
The sealing device is made from a composite material comprising a rigid substrate (such as metal or plastic) and a resilient coating (such as elastomer or rubber) applied to at least one major surface. This composite structure provides both the rigidity needed for automated handling and the resilient properties needed for sealing deformation.
2Ease of manufacture
If traditional die cutting is used on composite materials, then cutting can be performed, but the rigid substrate becomes warped or bowed
Solution Approach 1:
The cutting process is segmented into two separate operations: first cutting the resilient coating material, then cutting the rigid substrate. This is achieved by providing a punch with two cutting edges at different distances from the punch face, allowing sequential cutting without warping the substrate.
Solution Approach 2:
The cutting approach moves from a single-plane cutting method to a multi-dimensional approach where cutting occurs at different depths and sequences. The first cutting edge cuts the coating while the second cutting edge cuts the substrate, effectively separating the cutting actions in the depth dimension.
3Ease of manufacture
If rotating blades are used to cut sheet metal, then cutting can be performed, but the process is slow and costly
Solution Approach 1:
The traditional rotating blade cutting mechanism is replaced with a stamping/punching mechanism. The punch with aligned cutting edges stamps through the composite material in a single rapid motion, eliminating the slow rotating blade process while maintaining cutting effectiveness.
4Reliability
If lateral projections are added to sealing devices, then they can grip groove walls, but they increase cost without solving fitting difficulty
Solution Approach 1:
The rigidity parameter of the sealing device is changed by using a rigid substrate instead of purely flexible material. This parameter change allows the device to maintain its shape during automated fitting while still providing sealing function, eliminating the need for additional gripping features.
Data Source
AI summary
Then invention relates to seals, methods for making seals and devices for making seals wherein the seals comprise a rigid substrate with two substantially parallel major surfaces (106, 108) wherein said surfaces are separated by a cut surface (110). The cut surface (110) comprises a first burnished region (119) of height p1 and a second burnished region (121) of height p2 wherein said first and second burnished regions are separated by a rough breakout (123) of height b.