How are bonded seals made?

How are bonded seals made?

Bonded seals, also known as Dowty seals, are critical components that are often used in applications where a leak-free seal is required. Bonded seals consist of a rubber seal bonded to a metal washer and are commonly used in hydraulic and pneumatic systems. In this article, we will explore how bonded seals are made and the materials used in their manufacturing.

The Materials Used in the Manufacturing of Bonded Seals

When manufacturing bonded seals, two materials are used; the metal washer and the rubber seal. The metal washer is usually made from carbon steel, stainless steel, or aluminum, while the rubber seal is typically made from materials such as Nitrile, Silicone, or Fluorocarbon.

The Manufacturing Process of Bonded Seals

The process of making bonded seals involves two main stages: molding and bonding.

Stage 1: Molding

In this initial stage, the rubber seal material is injection-molded into the desired shape. The mold is typically made from high-strength aluminum to ensure precise shape replication over repeated manufacturing cycles. Once the rubber has been poured into the mold, it is heated and pressurized to ensure uniformity across the entire seal. The cooling process then begins, and the newly molded seals are placed on a conveyor belt to transport them to the next process.

Stage 2: Bonding

In this stage, the metal washer and molded rubber seal are brought together, and bonding occurs. Before bonding, the metal washer is cleaned and coated with a specialized adhesive. Depending on the application, solvent-based or heat-activated adhesives may be used.

The rubber seal is then placed on top of the washer, and a compression load is applied to press the seal onto the washer at a specific pressure. The newly bonded sealed is then placed into an oven to cure and solidify the adhesive. Once it is finished curing, the seal is inspected to ensure high-quality standards have been met, and it is ready for packaging and shipping.

The Advantages of Bonded Seals

Bonded seals have several advantages over other types of conventional seals. They are designed to provide reliable and long-lasting sealing solutions in high-pressure or high-temperature applications. Here’s a look at some of the advantages of using bonded seals:

1. Cost-Effective

Bonded seals are cost-effective compared to other alternatives, such as gaskets and O-rings. They can significantly reduce assembly costs due to their one-piece design.

2. High Chemical Resistance

Bonded seals are resistant to chemicals, making them an ideal sealing solution for use in hydraulic and pneumatic systems.

3. Withstand high temperature and pressure conditions

Bonded seals are designed to withstand high temperatures and pressure conditions making them ideal for use in extreme environments where other seals may fail.

4. Easy to handle

Bonded seals are easy to handle since they are designed to fit snugly into place without interfering with the system's installation process.

5. Versatile

Bonded seals are versatile, making them suitable for use in different applications where different kinds of seals are required.

Conclusion

Bonded seals are critical components that play a critical role in hydraulic and pneumatic systems. They are also widely used in the automotive, aerospace, and marine industries, amongst others. They are designed to provide reliable and long-lasting sealing solutions that withstand high pressure and temperature conditions, making them indispensable in various applications. The manufacturing process of bonded seals involves two main stages; molding and bonding. The process is cost-effective and results in a high-quality seal that is resistant to chemicals and easy to handle. Bonded seals are a versatile product that offers an effective sealing solution for many applications.