Multiple Durometer Seal Cooling Segmentation
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Solution Overview
Problem
Conventional co-extrusion processes for making bulb seals result in cooling differentials between multiple durometer materials, leading to adverse effects on part dimensions, tolerances, and structural integrity due to uneven cooling rates and complexities in processing.
Innovation Solution
A method involving upstream and downstream extrusion and cooling processes with separate calibrator devices and cooling tanks to manage cooling expansion and differentials between structural and sealing portions, ensuring optimal cooling and profile maintenance before cutting the seals to length.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional co-extrusion process is used to make bulb seals with multiple durometer materials, then the mounting portion provides structural strength and the bulb portion provides sealing function, but the different cooling rates between the two portions cause dimensional inaccuracies and compromise part integrity
Solution Approach 1:
The patent divides the cooling process into two separate segments: the mounting portion is cooled in a first cooling tank while the bulb portion is cooled in a second cooling tank. This segmentation allows each portion to be cooled at its optimal rate independently, preventing the dimensional inaccuracies and warping that occur when both portions are cooled together in a single tank.
2Ease of manufacture
If conventional co-extrusion process with single cooling tank is used, then processing is simpler, but the continuous extrusion strip prevents effective cooling of the bulb portion from the inside
Solution Approach 1:
The patent separates the cooling function into two independent cooling tanks, allowing the bulb portion to be effectively cooled from both the outside and inside surfaces. The first cooling tank cools the mounting portion while the second cooling tank cools the bulb portion, ensuring uniform cooling throughout the entire seal structure.
3Force
If different durometer materials are used for mounting and bulb portions, then the mounting portion has greater stiffness for installation and structural strength, but the cooling differentials adversely affect part dimensions and tolerances
Solution Approach 1:
The patent applies different cooling conditions to different parts of the seal based on their specific requirements. The mounting portion, requiring high stiffness, is cooled in the first tank with conditions optimized for rigid materials. The bulb portion, requiring flexibility, is cooled in the second tank with conditions optimized for softer materials. This local customization of cooling parameters maintains both the required stiffness and the dimensional precision.
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 approach helps in producing high-quality multiple durometer seals with improved dimensional accuracy and structural integrity by separately cooling the structural and sealing portions, overcoming the limitations of conventional co-extrusion methods.
Implementation Method 1
provide a cooling medium flow thereto
Data Source
AI summary
Method for making multiple durometer bulb seals and any other types of multiple durometer seals and moldings includes cooling separately at least one structural member and at least one sealing portion, which have different durometers and shapes. At least a first extrusion is drawn through an extruder, forming a structural member profile and the extruded material is pulled along a longitudinal axis to a first calibrator device and first cooling tank to cool the structural member profile to a predetermined temperature. Cooling medium directly contacts the outer and inner surfaces of the first profile. Downstream, the sealing portion is extruded and affixed onto the cooled structural member and pulled further downstream to a second calibrator device and through a second cooling tank to cool the final profile a predetermined amount. Disparity in cooling expansion and cooling differential between the multiple durometers and shapes is avoided or overcome.