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
Special O-rings for an automotive application Our customer manufactures high performance oil and vacuum pump solutions, and approached our engineers with a new O-ring for their automotive application. The application Our customer required an FKM (Viton™) 60 shore O-ring to meet Porsche material specification PN707 Class 2 (Oil), Class 5 (Fuel/FAME mix) and Class 12 … Continued
High speed Rotary seals for electric vehicles The electric vehicle industry is growing; global manufacturing and registrations of electric vehicles is increasing exponentially each year. Our engineers have extensive experience in designing seals for automotive applications, but we still find new challenges involved in sealing components within hybrid, hydrogen fuel and full battery powered electric … Continued
Silicone O-rings for De Soutter EcoPulse™ lavage system De Soutter Medical Ltd specialises in the development, production and worldwide distribution of high performance orthopaedic tools for surgical procedures, offering their customers a comprehensive range of technically innovative and high quality products. The company approached us to manufacture two different sized Silicone O-rings for the ECO … Continued
Gold plated metal seals for Oil & Gas couplings Our customer designs and manufactures hydraulic distribution products and systems. These are used to control subsea production systems for the offshore energy industry globally. We explore here how our gold plated metal seal solution suited the application due to its malleability and suitability for slightly dynamic operation. … Continued
PTFE Rotary seal for oil & gas drilling tool Our customer designs and manufactures a leading range of unique downhole technology and drilling solutions that contribute to a net zero energy industry. Read on to find out about our PTFE rotary seal solution for their application. The application Our customer tasked us with developing a … Continued
Why use 2-shot moulding? 2-Shot moulding is a manufacturing process that allows the co-polymerisation of hard (or soft) plastics and thermoplastic elastomers (TPE’s). We use the 2-Shot manufacturing approach to deliver engineered parts that perform a critical sealing function. What is 2-shot moulding? A 2-Shot mould is designed with a top and bottom cavity. During … Continued
Why use PTFE seals? Polytetrafluoroethylene (PTFE) is a thermoplastic polymer. PTFE seals can be used in a variety of sealing applications. It’s suitable when application conditions exceed parameters of elastomeric seal use but not to the extent of a metal seal. What is PTFE? It has a high melting point (342 °C) and morphological characteristics. … Continued
Why use metal seals? Using metal seals as an engineered sealing solution is appropriate when it’s not possible to use elastomeric or polymer seals. This will be because of extremely demanding application requirements. For example, these could include applications with extremely high temperatures (300°C upwards) and pressures, intense radiation, cryogenic conditions or highly aggressive chemicals. … Continued
Why use Push-in-Place gaskets? Where a seal groove follows an irregular path or profile, a common sealing solution is to design a custom Push-In-Place (PIP) gasket. This will have the same profile as the centre line of the groove, and simply drops into place, retained by the features of its own design. Gasket sealing overview There are … Continued
Where a seal groove follows an irregular path or profile, a common sealing solution is to design a custom Push-In-Place (PIP) gasket. This will have the same profile as the centre line of the groove, and simply drops into place, retained by the features of its own design.
There are many ways to seal the static join between two components. This could be to keep fluids inside a cavity, or to keep fluids or contaminants out of a device or assembly. The options will vary from simple O-rings, moulded elastomer gaskets and flat sheet style materials, to liquid gaskets (or RTV’s).
As with all sealing applications, the optimal sealing solution is designed by first reviewing the application conditions. These include temperature, pressure, fluid exposure etc. Other variables such as life requirement, equipment serviceability and seal compression set will all be considered. Arguably though, compared to other sealing applications there are considerations when designing face, cover or flange sealing solutions. It is imperative to consider the packaging requirements and assembly issues of gasket sealing options. For example, if there is a need to avoid or seal around bolt holes (or other retaining/clamping devices). Additionally, consideration around optimizing hardware wall sections or depths can play an important part in choosing the most suitable gasket sealing technique.
With the right combination of application conditions, an O-ring style approach to sealing may be the most appropriate. O-rings tend to require relatively shallow grooves compared to their cross section in one half of the assembly. In cases where the groove is round in plan view – they can be a good solution.
However, in cases where the groove follows a more irregular path or profile (frequently referred to as a “racetrack”) the O-ring can sometimes pop out in places. This will be often where the two housing parts are being brought together. A common solution is designing a custom moulding with the same profile as the centre line of the racetrack groove. This will simply drop into place.
A similar approach is used when the application or hardware constraints steer the design towards a gasket that has a greater cross section depth compared to the width. This would typically be designed so the centre line of the gasket matches the centre line of the groove plan profile – again so that it drops easily into place.
An inherent problem with gaskets that can drop into place is that often, they easily drop out of place too. This can occur when the component needs to be inverted or has the potential for rough handling during assembly. Consequently, the gasket may become partially or fully dislodged from the groove, which results in a badly sealed interface. The best solution to this issue is to incorporate retention pips or bumps in the gasket design. This is a solution known as Push-In-Place (PIP) gaskets. These require a distinct force to put them into the groove, and as a result require more than just gravity to get them out of the groove.
There are other less effective solutions for tricky groove sealing, such as the use of a sticky grease, or the use of an adhesive. These can bring compatibility and health and safety issues to consider. Additionally, the risk that any contaminant could keep the gasket off the surface that it’s supposed to be sealing against. As a result, the integrity of the seal can be severely compromised.
Neither of these approaches can be recommended. Instead, the use of retention pips is a safe and secure way of ensuring the gasket remains in the groove.
To determine the optimum number, size and position of the retention bumps, Finite Element Analysis is used. This ensures that they provide sufficient squeeze to prevent the gasket being easily dislodged, whilst not overfilling the groove space with seal material or interfering with the seal compression footprint against the hardware faces.
The bumps can be strategically positioned to control any distortion of the gasket under pressure or temperature conditions. For example, low temperature conditions can shrink the gasket and tighten the radius it adopts around a bend in the racetrack profile. This can reduce the seal compression locally and potentially create a leak path.
By positioning retention bumps at either end of the bend, the thermal contraction will be controlled to minimize leakage risk. Effective retention ensures that if the part needs to be inverted (which could be the preferred assembly method for practical reasons), or is subject to rough handling – the gasket remains correctly located in the groove.
For large gaskets this is normally the most effective solution. On smaller gaskets (particularly those located well inside the periphery of the assembly), there is a significant risk of a dislodged gasket being totally undetected unless using a PIP gasket design.
It is possible to include tell-tale signs on a gasket design. For example, if a part of the elastomer gasket protrudes sideways through a gap in the housing wall the presence of the gasket can be checked. This will be either with the human eye or an automated vision system. However, this does not ensure correct seating all around the gasket length. Additionally, it cannot be used for internal gasket locations. In these cases a missing or badly fitted gasket would only be discovered during post-build testing, or even worse with a machine failure at a customer.
If included at the design stage, the small additional tooling and material costs associated with a PIP gasket are negligible compared to the costs of an impossible assembly scenario, strip and re-build costs on the assembly line, or the consequential costs associated with failure of an assembly once delivered to a customer.
More information on PIPs and gaskets can be found HERE