CGR Products News Release: Growth Leads to a 30,000 sq ft Expansion and New High Volume Manufacturing Machinery
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Many variables can affect gasket sealing such as internal pressure, temperature, gasket design, and flange load. Sometimes it is necessary to dig a little deeper into the actual sealing picture when a difficult or critical sealing situation is encountered. In this article, we will explore a process we call “Fuji Testing”.
Fujifilm Prescale is a polyester based film that contains a layer of tiny microcapsules. The application of force upon the film causes the microcapsules to rupture, producing an instantaneous and permanent high resolution “topographical” image of pressure variation across the contact area. The use of this tactile sensor film is one method CGR Products uses to help customers see a “Static” picture of how the gasket is sealing in the current application.
We place the Fuji film between any two surfaces that touch, mate or impact. Apply pressure, remove it, and immediately the film reveals the pressure distribution profile that occurred between the two surfaces. Like litmus paper, the color intensity of the film is directly related to the amount of pressure applied to it. The greater the pressure, the more intense the color.
The principle way in which CGR Products uses Fuji film is to determine if the current gasket design is producing an acceptable seal to satisfy the customers’ requirements. In our example below, you are looking at a currently designed gasket where its highest pressure points are at the bolt holes. The bolt pressure points left a softer area in the middle of the flange.
If it is determined that the sealing pressure revealed by the Fuji film is not acceptable, CGR Products can use the film data to determine a possible revised gasket design. These tests can also reveal that a material change is all that is needed to satisfy the sealing requirements. Using the same example, this is CGR Products proposed design and material change after Fuji analysis.
To answer the question as to whether a Fuji analysis is right for you, Ask yourself if the potential warranty cost to your company is worth the time and effort. Let CGR Products help with your sealing issues so we can work together to solve potential warranty problems before they occur. Feel free to contact us with questions or dig deeper into our capabilities by clicking on our website.
Our Material of the Month series spotlights some of our favorite materials and their unique applications. This month, we’re discussing Felt.
Felt is a very versatile and resilient industrial fabric that is manufactured using different processes.
Needle Punch Process:
A fiber such as polyester is interlocked using a machine with thousands of needles moving in an up and down motion. Heat is then applied using a calendar roll to make a smoother surface and remove fuzziness from the felt. Calendaring can also be used to produce a firmer sheet. A binder can be added to felt that needs to be thermo-formable.
Wool or wool blended with other yarn are woven into cloth and then felted using steam and pressure to interlock the fibers.
Wool fibers or wool blended with other fibers are pressed together with steam and pressure that allows the fibers to naturally interlock.
Vibration dampening gaskets, wheel well liners, trunk and deck liners, under carpet padding, and noise absorption.
Vibration dampening gaskets, noise reduction, and lint and air seals.
General Industrial Applications
Industrial sander backing pads, floor protection pads, and oiler pads for slitting and friction applications.
As flexible material specialists, the CGR team offers years of experience in converting felt into components to fit specialty projects. Our in-house precision cutting services include rotary and flatbed die cutting, kiss cutting, slitting, splitting, knife cutting, and more.
For more information about applications and fabrication possibilities, visit our Materials Page. To discuss any Felt options for your next project, please reach out to our team today.
Before starting a die cutting project it is important to discuss all specific project requirements — including whether rotary die or flatbed die cutting is the best fit for the job. Each cutting method has its own distinct benefits based on production size, costs, and material.
Main Benefits: Holds tight tolerances and ideal for kiss cutting
Best Used for: High-volume orders
How It Works: Rotary die cutting, a highly accurate cutting method, is very cost effective on high-volume orders and produces less waste compared to other methods. As shown in the video, the machine is fed a roll of material which is then passed through the rolling die. This cuts the desired shape from the material and the waste is disposed of into a catcher.
Main Benefits: Provides a more cost-effective option with lower tool and die costs
Best Used for: General cutting and low-volume orders
How It Works: With flatbed die cutting, material shapes are stamped out using steel rule dies and hydraulic presses. This method allows for easy hole removal and web removal from parts, along with quick changeover times to increase efficiency.
CGR’s team of engineers makes sure to match your project’s needs with the right die cutting machine for the job. The products we die cut from a variety of flexible non-metallic materials can be supplied in continuous rolls, sheet form, or individual parts for your unique application.
Ready to get started? Visit our Supplier Material Library to find your material and contact us about your next project.