Splicing

We use four methods of splicing products, depending on run quantity, cost, material and performance required:

1. Film Splicing
2. C-Press
3. Vulcanizing
4. Cold Bonding

1.  Film Splicing
What makes film-splicing such a unique and dynamic process is that it eliminates the need for applying adhesive and requires no secondary trimming of flash (net molding). No inserts are required for splicing bulb seals, and therefore cycle times are faster versus traditional molding. Typically, an insert is placed inside the profile to be vulcanized. Once the part has been vulcanized, an incision is made to remove the mold, which must be resealed. This process can become tedious for large volumes, resulting in higher costs. Since film-splicing requires no insert, the first splice is the last splice! Having a one-step process increases productivity and eliminates the possibility for error. The result is an automotive-quality gasket. The film-splicing machine also has a unique cooling ability that allows us to splice taped profiles without compromising the adhesive ability of the tape.

2. C-Press (Molding)
This process involves creating a joint between two lengths of a profile by molding uncured compound directly onto the lengths to create a molded joint. The two ends of the profile are placed such that they fill the straight section of the mold. The uncured compound is placed in the empty, angled space in the cavity. The heat and pressure from the mold soften the compound allowing it to flow through the cavity. The part is left in the mold for a specified curing period. When the part is removed and cooled, the result is a permanent and precise joint.

3.  Vulcanizing
Vulcanizing is like hot gluing. This process is most often used to make O-rings. A small amount of adhesive is applied to a length of profile. The ends are pressed together and the joint is placed in a hot mold. Heat activates the glue, and pressure from the mold ensures the joint will be consistent with the dimensions of the profile. When the product is removed and cooled, the result is a reliable splice. This is an excellent and very effective process for splicing solid or sponge products with no internal cavity.

4.  Cold Bonding
For this process, cutting of the profile can be done by our water jet machine to obtain a smooth edge for bonding, with very precise angles. Cutting done by hand or guillotine often results in beveled, uneven ends; when these ends are bonded, the result is an incomplete splice. Fissures in the joint can compromise reliability and the splice easily falls apart. With a clean cut, the two mating surfaces are easily bonded and the part is ready for both dynamic and static applications! The joint is made by applying a quick-setting adhesive to the profile. The ends are pressed together and held for only a few seconds. The adhesive bonds almost instantly! This can be done with two lengths of profile to create a corner joint, or with one length, bonded end to end to create an endless ring.

This economical process can be used for low volumes to avoid expensive tooling costs.