UV-Curable Gasket Shaping Tool for Precision Sealing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for producing gaskets, such as injection molding, face challenges in filling small cavities due to limited pressure and require precise clamping, which can lead to inaccuracies and inefficiencies, especially when producing gaskets for small dimensions used in vehicle drive trains and fuel cells.
Innovation Solution
A method using a UV-transparent shaping tool with a cavity that is filled with UV-curable sealing material through screen printing, allowing the component to be placed on top and cured with UV irradiation, eliminating the need for pressurized filling and clamping, and utilizing flexible materials like silicone for easy removal and precise alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If injection molding method is used to fill small cavities, then gaskets can be produced on components, but the filling process requires high pressure and precise clamping which limits the method's effectiveness for very small dimensions
Solution Approach 1:
The process is segmented into two independent stages: first filling the mold cavity with sealing material under atmospheric pressure, then separately curing the material with UV irradiation. This segmentation eliminates the need for high-pressure filling while maintaining the ability to produce precise gaskets on small components.
Solution Approach 2:
The mechanical pressure-based injection molding system is replaced with a UV-curing-based system. Instead of using high pressure to force material into the cavity, the patent uses UV irradiation to cure the material in place, eliminating the mechanical pressure requirement and enabling precise production on very small components.
2Productivity
If pressurized filling is used to inject sealing material into small cavities, then gaskets can be formed, but the component and tool must be clamped firmly together which increases device complexity
Solution Approach 1:
The complex mechanical clamping and pressurization system is replaced with a simple UV irradiation system. The sealing material is applied to the component surface without requiring firm clamping, and curing is achieved through UV light exposure, dramatically simplifying the device while maintaining production efficiency.
Solution Approach 2:
UV irradiation serves as an intermediary mechanism that replaces the need for mechanical clamping and pressurization. The UV energy acts as the mediating force that cures the sealing material in place, eliminating the need for complex clamping mechanisms while maintaining productivity.
3Manufacturing precision
If injection molding is used for small cavity filling, then gaskets can be produced, but the process requires precise alignment and clamping which reduces ease of operation
Solution Approach 1:
The process is divided into simple sequential steps: apply sealing material to the component, position the mold cavity over the material, and irradiate with UV light. This segmentation into simple, independent steps eliminates the need for complex alignment and clamping operations while maintaining manufacturing precision.
Solution Approach 2:
The mechanically complex injection molding process is replaced with a optically-based UV curing process. The sealing material is applied directly to the component without requiring precise mechanical alignment or clamping, and curing is achieved through UV irradiation, greatly simplifying the operation while maintaining 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
Enables pressure-free filling and precise production of gaskets of arbitrary heights, particularly suitable for small dimensions, with improved accuracy and reduced tool and process costs, while avoiding the limitations of conventional injection molding.
Implementation Method 1
the material used for the gasket is a UV-curable sealing or gasket material
Data Source
AI summary
The invention relates to a method for producing a gasket on a component using a shaping tool, wherein the material used for the gasket is a UV-curable sealing or gasket material, and wherein the shaping tool comprises an upper face and a lower face and at least one cavity which is open toward the lower face of the shaping tool and which is provided for filling with the gasket material, and wherein furthermore the shaping tool is made of a UV-transparent material at least in the region of the cavity, comprising the following steps in the order indicated:1. introducing the gasket material into the cavity of the shaping tool;2. placing the component onto the lower face of the tool provided with the gasket material;3. pressing the component onto the tool;4. curing the gasket material by way of UV irradiation; and5. removing the tool from the component and the gasket joined thereto.The invention further relates to a shaping tool for use in such a method.