Segmented Rubber Gasket on Base Material for Sealing
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Solution Overview
Problem
Conventional gaskets made of rubber-like elastic materials for sealing gaps in resin materials face issues with high manufacturing costs, deformation of thin or fragile members, and reduced sealing performance due to permanent strain, especially when used with low-rigidity base materials.
Innovation Solution
A sheet-like gasket with a continuous projection portion made of rubber-like elastic material integrally formed on a sheet-like base material, using two metal molds for pinching and punching into a fixed shape, which reduces manufacturing costs and prevents unnecessary strain on the base material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a sheet-like gasket with a gasket portion is bonded on a surface of a sheet-like base material, then manufacturing cost is reduced, but repulsive force on the other member increases causing deformation
Solution Approach 1:
The gasket portion is divided into multiple projection portions that extend in the thickness direction of the base material. These segmented projections reduce the contact area with the other member, thereby reducing repulsive force and preventing deformation while maintaining sealing functionality.
Solution Approach 2:
The projection portions are strategically positioned at locations where sealing is required, concentrating the sealing function at specific points rather than across the entire surface. This localized approach reduces overall repulsive force on the other member while maintaining effective sealing at critical areas.
2Ease of manufacture
If a sheet-like gasket with a gasket portion is bonded on a surface of a sheet-like base material, then manufacturing cost is reduced, but sealing performance deteriorates due to permanent strain
Solution Approach 1:
The gasket portion is segmented into multiple projection portions, which reduces permanent strain in the rubber-like elastic material by distributing deformation more evenly. This segmentation maintains sealing performance over time by preventing excessive strain accumulation in any single area.
Solution Approach 2:
The projection portions are designed to elastically deform under compression and recover when the load is removed. This dynamic behavior allows the gasket to maintain sealing pressure while minimizing permanent strain, ensuring long-term sealing reliability.
3Productivity
If the gasket portion is simultaneously formed on both front and back surfaces, then manufacturing efficiency is improved, but the sheet-like base material deforms due to low rigidity
Solution Approach 1:
The formation of gasket portions on both front and back surfaces is combined into a single simultaneous manufacturing process using a press. This merging of operations improves manufacturing efficiency by completing both surfaces in one step while the press provides sufficient support to prevent deformation of the low-rigidity base material.
4Reliability
If a metal mold is used to form a chevron gasket portion, then sealing performance is improved, but manufacturing cost increases due to requiring one mold per specification
Solution Approach 1:
A single press with standardized tooling is used to form gasket portions on sheet-like base materials of various specifications. This universal approach allows different gasket configurations to be produced using the same equipment, eliminating the need for dedicated metal molds for each specification while maintaining adequate sealing performance.
Solution Approach 2:
Instead of using expensive, durable metal molds for each specification, the invention employs simpler, less costly forming tools that can be easily adjusted or replaced. This approach trades the long-term durability of metal molds for lower initial cost and greater flexibility in handling various specifications.
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
The solution provides good sealing performance with low repulsive force, stable sealing over time, and flexibility in selecting base and rubber materials, expanding the gasket's range of use while avoiding deformation and excessive fastening, even in narrow spaces.
Implementation Method 1
a gasket portion which is made of a rubber-like elastic material and is integrally formed on at least one surface of the base material
Data Source
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AI summary
In order to inexpensively provide gaskets which have good sealing performance, and which fulfill various applications by simply stamping out sheet-like gaskets in accordance with specifications, a gasket is obtained by integrally forming, with a sheet-like base material, a gasket part made of a rubber-like elastic material on at least one surface of the base material, said gasket part being composed of continuous protrusions provided with a fixed pattern. The sheet-like gasket parts produced in this manner are capable of inexpensively providing gaskets which fulfill various applications by simply stamping out the sheet-like gasket parts in accordance with various specifications.