Resin Seal Ring Shape Forming with Segmented Temperature Control
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Solution Overview
Problem
Existing methods for forming synthetic-resin seal rings with abutment joint ends facing each other with a predetermined gap face challenges in achieving efficient and accurate shape formation, particularly in large-scale production, due to temperature inconsistencies and limited batch processing efficiency.
Innovation Solution
A method and apparatus where the seal ring is fitted into an annular gap between outer and inner circumferential jigs, maintained at constant temperatures above and below the glass transition temperature of the resin, allowing the seal ring to be sequentially heated and cooled to form the desired shape, preventing thermal history variations and enabling continuous processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the whole jig is heated by putting it in an electric furnace, then the seal ring can be formed in the desired shape, but it takes a long time to raise the temperature and temperature difference is generated between regions of the jig
Solution Approach 1:
The jig is divided into multiple heating zones with independent heating elements, allowing each region to be heated separately and simultaneously. This segmentation enables uniform temperature distribution across the entire jig while reducing total heating time, as multiple regions heat in parallel rather than sequentially.
Solution Approach 2:
The heating system uses independent temperature control for each heating zone, allowing precise adjustment of heating parameters. By changing the temperature parameters of individual zones rather than heating the entire jig uniformly, the system achieves both rapid heating and uniform temperature distribution.
2Productivity
If the jig is enlarged or the number of jigs is increased to process more products, then the number of members that can be processed increases, but the electric furnace and the like must be enlarged and jig put-in work and jig take-out work are increased
Solution Approach 1:
Multiple heating zones are merged into a single integrated jig structure, allowing multiple seal rings to be processed simultaneously in one jig. This combining approach increases productivity without requiring multiple separate jigs or a larger electric furnace, thereby reducing device complexity and operational overhead.
Solution Approach 2:
The jig is designed with universal heating capability across multiple zones, where a single jig can process multiple products simultaneously. This multi-functionality allows one jig to replace what would traditionally require multiple jigs, simplifying the overall system configuration.
3Reliability
If the abutment joint portion has the shape in which many joint surfaces are formed like step cut, then the abutment joint ends are easy to fix by heating, but high accuracy is necessary for the process
Solution Approach 1:
The heating system applies different temperature parameters to different regions of the jig, with localized heating zones positioned to heat specific areas of the seal ring. This local quality approach ensures that the abutment joint portion receives precise, controlled heating to achieve proper fixing without requiring excessive process accuracy across the entire component.
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 improves the dimensional accuracy and efficiency of seal ring shape formation, allowing for mass production while maintaining the predetermined gap between abutment joint ends, preventing them from being completely fixed together, and facilitating easy removal and improved roundness of the seal ring.
Implementation Method 1
the outer circumferential jig and the inner circumferential jig being maintained at a constant temperature higher than a glass transition temperature of a resin material for the seal ring in the heating region
Implementation Method 2
the outer circumferential jig and the inner circumferential jig being maintained at a constant temperature lower than a glass transition temperature of a resin material for the seal ring in the cooling region
Data Source
AI summary
A seal ring whose abutment joint portion is opened is fitted into an annular gap while the abutment joint portion is substantially closed. The annular gap is formed between an inner circumferential surface of a hole portion provided in an outer circumferential jig and an outer circumferential surface of an inner circumferential jig disposed in the hole portion, and has a heating region and a cooling region. The seal ring is passed through the heating region and then passed through the cooling region in the annular gap. The outer circumferential jig and the inner circumferential jig are maintained at a constant temperature higher than a glass transition temperature of a resin material for the seal ring in the heating region, and maintained at a constant temperature lower than the glass transition temperature of the resin material for the seal ring in the cooling region.