Gasket Manufacturing Using Molding Jig for Shape Correction
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Solution Overview
Problem
The existing method of manufacturing substrate integrated gaskets using a dispenser for applying liquid rubber results in unstable sealing performance and limited cross-sectional shape precision due to the dripping shape formed by wetting properties and surface tension, leading to inconsistent height and width in the cured gasket.
Innovation Solution
A method involving the application of a liquid molding material to a plate body using a dispenser, followed by lapping a molding jig with a corresponding groove pattern to correct and cure the application layer, ensuring precise cross-sectional shape formation, which can include using ultraviolet curable materials and burr grooves to manage excess material and prevent peeling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If liquid rubber is applied by dispenser without molding jig, then the application process is simple, but the cross-sectional shape precision and height stability deteriorate due to dripping shape formation
Solution Approach 1:
A molding jig is introduced as an intermediary tool between the dispenser and the substrate. The molding jig has a groove that receives the applied liquid rubber and guides it to form the desired cross-sectional shape, preventing unwanted dripping while maintaining process simplicity
Solution Approach 2:
The molding jig is prepared in advance with a groove structure that defines the target cross-sectional shape. This preliminary preparation allows the liquid rubber to be shaped correctly during application without requiring complex real-time control
2Productivity
If liquid rubber is applied by dispenser without molding jig, then the manufacturing process is fast, but the sealing performance reliability deteriorates due to unstable height and shape
Solution Approach 1:
The molding jig serves as a mediator that ensures consistent and reliable gasket formation during the rapid dispenser application process, enabling high productivity without sacrificing sealing performance reliability
Solution Approach 2:
The molding jig controls the physical parameters of the liquid rubber (shape, height, cross-section) during application, ensuring that each gasket meets specification requirements for reliable sealing performance
3Manufacturing precision
If molding jig is introduced to correct cross-sectional shape, then the precision and stability of gasket dimensions improve, but the device complexity increases
Solution Approach 1:
The molding jig only modifies the local region where the liquid rubber is applied, using a groove structure that precisely shapes only the necessary portions without requiring complex overall device design
Solution Approach 2:
The groove structure in the molding jig is pre-designed with the exact cross-sectional shape needed, eliminating the need for complex real-time shaping mechanisms and reducing overall device complexity
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 enhances the precision of the gasket's cross-sectional shape and height, achieving stable sealing performance and reducing molding time, while also allowing for the easy removal of burrs and prevention of peeling issues.
Implementation Method 1
the liquid molding material is constructed by an ultraviolet curable liquid rubber, and the curing of the application layer is achieved by irradiating ultraviolet light to the application layer via the molding jig
Implementation Method 2
lapping a molding jig over the plate body, correcting a cross sectional shape of the application layer to a cross sectional shape corresponding to the molding groove
Data Source
AI summary
A process for producing gaskets by curing a liquid molding material applied over a plate by a dispenser, wherein in order to improve accuracy in the cross-sectional shape and/or height of the gaskets, the process comprises the steps of: using a dispenser to coat the upper surface of a plate with a liquid molding material, and form a coating layer extending endlessly in a prescribed pattern; and overlapping a molding jig on the plate, the molding jig having in a lower surface a molding groove extending endlessly in a prescribed pattern corresponding to the coating layer, correcting the cross-sectional shape of the coating layer to a cross-sectional shape that corresponds to the molding groove, and curing the coating layer.