Precision Sealing for Naval Radar Slip Ring The application Our customer is a globally recognised leader in the design and manufacture of advanced slip ring systems and contactless rotary joints. Their technology ensures the reliable transmission of power, data, and media across a wide range of rotating interfaces. Read more about how our engineers developed … Continued
Using Finite Element Analysis (FEA) in seal design Finite Element Analysis (FEA) is a computerised modelling method for predicting how an object reacts to forces, whether directly applied or generated by pressure, temperature effects or vibration. FEA provides data to help predict how a product will function under those applied conditions. Additionally, it identifies areas where … Continued
Are all elastomers the same? Material hardness This is often the least considered property when selecting a material. In sealing applications, elastomer material hardness can impact assembly loads, seal friction and extrusion resistance. Softer rubber can better accommodate surface imperfections (especially when sealing low pressure gas). This means softer seal compounds can be used effectively … Continued
The importance of engineering tolerances What tolerances are we concerned with? We can start with the seal itself, and specifically the seal material, as almost all polymer seal materials contain multiple ingredients. For PTFE and polyurethanes this is typically 2 or 3 different elements. However, for an elastomer material as many as 30 different ingredients … Continued
Elastomer manufacturing moulding processes Compression moulding This is the simplest method of converting a piece of rubber into a finished seal product. The rubber compound is first mixed and prepared, and depending on the recipe can require up to 30 different individual ingredients. At this stage the curing (or vulcanization) of the rubber hasn’t yet taken … Continued
Polyurethane as a seal material The foam in your armchair. The strap on your wristwatch. The wheels on a supermarket shopping trolley and beyond; Polyurethane certainly has a diverse range of uses since its invention almost 85 years ago. Aside from day-to-day products; it is also a highly capable and versatile sealing material – and … Continued
Diaphragms for precise control in critical applications In applications that require precise and rapid pressure responses, our diaphragms offer an engineered sealing solution for high performance valves and actuators. Why use diaphragms? Diaphragms provide excellent sealing results in multiple applications. These include valves, actuators, pumps, pressure & flow control, pressure switches/sensors, dispensing, metering, ventilation, and … Continued
Supply Plus Ltd designs, manufactures, supplies and distributes safety and fuel delivery equipment, with brands including AS Fire & Safety, Bayley and Collins Youldon. They approached us to design a rotary seal to replace their existing solution which was causing leakage during downtime. The application Supply Plus initially approached us with a requirement for their … Continued
Special coated O-rings for renewable energy application Our renewable energy customer manufactures wind sensors for a variety of applications in different environments. This seal application, within ultrasonic wind sensors, is designed for wind turbine control. We explore here why special coated o-rings are needed for this application, regularly exposed to harsh conditions. The application For … Continued
Moulded gaskets for an automotive application An existing customer (an automotive manufacturer) approached our engineers with an application where they were experiencing failures of a seal designed and manufactured by another rubber seal provider. Here we explore more about our solution for a moulded gasket for this automotive application. The application This gasket is used … Continued
An existing customer (an automotive manufacturer) approached our engineers with an application where they were experiencing failures of a seal designed and manufactured by another rubber seal provider. Here we explore more about our solution for a moulded gasket for this automotive application.
This gasket is used within a valve housing in an automotive application. The original competitor gasket was experiencing failure at the “T-junction” areas of the seal. Therefore, our customer had experienced chronic failures of their existing design at high temperatures and high pressures.
A pulsating pressure of up to 50 Bar and temperatures up to 150°C provide an extreme environment for the seal. Consequently, our engineers reviewed the existing gasket design and application conditions and recommended an increase in height of 0.40 mm.
This was to increase the compression and improve the sealing function. Additional beads were also added to further stabilise the gasket in the groove.
We manufactured prototype parts using a single-cavity soft tool and sent them to the customer for in-house testing and validation. The prototype gaskets nearly passed testing but fell just short of the 50 Bar pressure requirement at 150°C, achieving 42 Bar instead. Even so, they significantly improved on the performance of the customer’s original gasket.
Upon analysis of customer test data and furthermore by reviewing images of the tested parts, improvements were needed. We determined there were areas where the gasket was sliding in the groove and then shearing as the pressure pulsed. To resolve this issue, our engineers added beads to the rear of the T-intersections of the gasket. This provided additional support, further stabilising the gasket at the high-pressure stress points in the groove. This reduced the amount of movement within the housing.
Furthermore, the number of additional beads added needed to be balanced carefully with calculations on groove fill. Further development captured the cleanliness requirements and altered radii on the beads.
With the new design approved, the customer moved to production tooling stage and sample parts were produced to PPAP Level 3. These parts have since been approved and full production quantities have been ordered manufacturing builds in 2022.
For more about our mouldings & gaskets, see our dedicated page HERE.