With the 3K control piston composite part, which combines two different elastomer compounds, we have developed a product that impresses with both its advanced technology and innovative tool design.
The challenge: multi-component composite parts with maximum sealing performance
The manufacture of 3K composite parts places the highest demands on technology and processes. Our motto, ‘The right rubber solution for every challenge’, is particularly apt here, where two elastomer compounds and an aluminium carrier part must be combined in a single step.
The solution: an innovative 3K composite component
On one side of the control piston, a flat seal is formed against a sealing plunger. To ensure a reliable and durable seal, this area is overmoulded with NBR 85 Shore A. On the opposite side is a radial shaft seal that seals against the running surface in the guide bushing. Due to the higher elasticity required, this sealing area uses a special NBR 70, which is bonded to the metal component using compression moulding. With a compression set of just 11% after 72 hours, both materials guarantee a durable, reliable seal. The hard-anodised aluminium support component ensures additional precision and stability.
Why NBR 85 and NBR 70 are the perfect choice
Choosing the right elastomer is crucial to the proper functioning of the control piston. NBR 85 offers stability and durability, whilst NBR 70, with its higher elasticity, ensures optimum sealing performance. Combined with aluminium, this creates a high-precision composite component for applications in control valves or field modules that perform decentralised control tasks for actuating pneumatic or hydraulic components.
Manufacturing with intelligent mould concepts
Production requires precisely thought-out mould designs. Many important details must be taken into account to ensure the highest quality. How should the carrier part be positioned in the mould so that it can later be demoulded without damaging the sealing and guide surfaces? Where must sealing areas be taken into account? What injection options are available, and where might air pockets form that could jeopardise the result?
Our experts impress with their many years of experience in the tool design of intelligent tooling concepts, which are initially used for prototypes and can then be easily scaled up for series production. Quality and cost control remain the constant focus throughout.
ZORGE benefits at a glance
- Highest precision: 3-component composite parts for the most demanding sealing requirements
- Dual sealing action: Two elastomer compounds in a single component for maximum sealing performance
- Durability: Low compression set for high recovery force
- Customised solutions: Adaptation of the design to specific requirements
- Scalability: From prototypes to series production with a focus on quality and cost
Are you looking for a partner for complex sealing requirements?
Contact us, and let’s solve your challenge together!