Category Archive: Uncategorized

Die Cut Solutions using Rogers Materials for Electric Vehicle Batteries

As a Preferred Converter for Rogers Corporation, CGR Products is your go-to converter of die cut flexible materials for Electric Vehicle (EV) Batteries.   CGR Products provides solutions for thermal runaway, sealing out elements, heat shielding, gap fillers, battery cushioning, and more.  CGR Products is a leading converter to solve challenges for EV battery manufacturers.

 

Die Cut Battery Pads & Cushions

CGR Products die cuts battery pad cushions and compression pads using Rogers materials that must be firm enough to hold the battery cells in place, while also maintaining compression as the cell expands and contracts.  Battery pads made from PORON polyurethane and BISCO silicone foams have a unique ability to produce a very consistent level of force across a range of compressions.  PORON pads and BISCO silicone battery compression pads are die cut at CGR Products using a variety of sophisticated machinery to hold tight tolerances per the battery manufacturer specifications. Additionally, Rogers die cut foam pads isolate and dampen noise and vibrations in the battery.

Die Cut Battery Seals

Rogers ev battery diagram

Rogers Corporation Battery Materials Diagram

Sealing the battery enclosures from potential damage caused by the elements and road debris is critical to its operation.  CGR Products die cuts a variety of PORON and BISCO materials to protect sensitive components from water, dust, and the elements. Gaskets fabricated from BISCO silicone material seal out water, dust, and debris while providing exceptional temperature and UV resistance. PORON polyurethane material is designed to reliably hold a consistent force, keeping battery cells aligned, sealed from dust and fluid, and isolated from the damaging effects of vibration.

 

Die Cut Venting Films

EV Batteries need protection from harsh external conditions. Usually located on the underside of the vehicle, EV battery enclosures protect the cells from exposure to water, dust, debris, and other elements. EV battery enclosures also undergo temperature and pressure changes that can lead to problems without proper venting that can lead to potentially dangerous thermal runaway conditions. Die cut seals are required for venting to reduce heat and protect against environmental elements

Rogers DeWAL® V-Series venting membranes are engineered to vent and protect a wide range of critical enclosure applications. These venting membranes can be die cut and leverage the unique properties of expanded polytetrafluoroethylene (ePTFE) to enhance heat and air ventilation while protecting sophisticated electronics sealed in automotive electrical, telecommunications, and lighting enclosures.

Working with CGR Products

CGR Products ev batteriesOnly a select few companies that partner with Rogers are recognized as a Rogers Preferred Converter.  A Preferred Converter is the highest designation Rogers gives a company that demonstrates expertise in converting capabilities and holds to the highest standards.

At CGR Products, we have maintained Rogers Preferred Status since the inception of the program.  We continuously thrive to stay on the cutting edge of technology and converting processes.  Our capabilities allow us to convert Rogers products to your exact specifications at prices that will keep you competitive in your market space.

To learn more about Rogers Corporation’s portfolio of EV Battery material options, visit the Battery Applications Page.

Component Foams Specifically Engineered for Automakers

Guest Author: Isabell Wright, Armacell .

For most major car makers, all parts must be made from materials that are on their approved source list. It’s a competitive business and only the best suppliers with a proven track record of quality, new technology, on-time delivery and service will make the cut. Once a material has been included on the approved source list or our fabricator partners have been selected as preferred suppliers, the task is not over. We must continually maintain or improve our specs to stay competitive and meet the high expectations of auto makers and their supply chain.

Armacell’s foam is used in automotive components such as gaskets for sealing out water, air, dust or noise.

FIAT CHRYSLER AUTOMOBILES

In the 1930’s Chrysler was known for its iconic Chrysler building in New York City and affordable luxury vehicles. Now they are known as a maker of family cars including a hybrid. Armacell makes a number of materials on the approved source list for FCA including Monarch 3091® and EnsoLite® EF0 which meet the MSAY 430 spec. Both have the necessary resistance to UV, weathering and acid. They meet the horizontal burn requirements for interior automotive gaskets. EnsoLite EF0 has the added benefit of being a super soft and conformable, semi-closed cell, crushed foam that works well in applications that require the material to spring back to its original thickness.

Armacell made more than 6 million square feet of EnsoLite SF0 in 2018

 

TOYOTA MOTOR CORP

For 75 years, Toyota has disrupted the market and revolutionized manufacturing. As a maker of cars that are known for efficiency and reliability, Toyota stands by their brand. It makes sense that they insist on suppliers that do the same. Armacell makes a number of products that meet the tough Toyota TSM 1501G spec for automobile parts. Monarch 8002 is a 100% EPDM bun that has a dependable resistance to corrosive acids, UV and weathering. That means the material will hold up to the abuse auto parts take over time. EnsoLite IG1, manufactured in continuous rolls or sheets, has excellent resistance to oil, fuel and flame. These qualities make EnsoLite and Monarch great choices for gaskets and seals in automotive design.

 

Click Here to Download the Full Automotive Component Foams PDF.

To learn more about Armacell Products, visit their website – Armacell

To go along with the Component foams, Avery Dennison has put together an in-depth adhesive bonding study which can be found Here.

As flexible material specialists, the CGR Products team offers years of experience in converting foam material into gaskets and components. Our in-house precision cutting services include rotary and flatbed die cutting, kiss cutting, slitting, splitting, knife cutting, and more.  For your next foam project, Contact Us today.

 

Die Cut Solutions for Electric Vehicle Batteries

CGR Products is your go-to converter of die cut flexible materials for Electric Vehicle (EV) Batteries.   CGR Products provides solutions for thermal runaway, sealing out elements, heat shielding, gap fillers, battery cushioning, and more.  As Preferred Converters for many of our suppliers, CGR Products is a leading converter to solve challenges for EV battery manufacturers.

Thermal Management

Thermal management of EV batteries and their systems are a top concern of electric vehicle manufacturers.  Battery packs must operate at a proper temperature and at optimal pressure via the use of battery compression pads. Electric vehicle battery makers incorporate the use of specialty materials between cells and modules – or around the pack – to help slow down or eliminate the propagation of thermal events.

CGR Products works with EV battery manufacturers to die cut and supply items such as:Urethane foam ev battery pads

  • Battery Pack Heat Shields
  • Cell Separators
  • Electrical Insulation
  • Thermal Gap Fillers
  • Thermal Runaway Protection Pads

 

Battery Compression and Vibration Pads

Battery pad cushions, or compression pads, used inside an EV pouch cell battery pack must be firm enough to hold components in place and compressible enough to withstand dimensional changes to the pouch cells over the life of the battery.  CGR Products die cuts materials with unique abilities to produce a very consistent level of force across a range of compressions.

Batteries also need to be protected from impact and vibration. Vibration must be managed both within the pack and between the pack and the vehicle. CGR Products provides solutions for vibration dampeners and impact isolators via die cutting urethane and silicone foams.

Battery Ingress Protection

Silicone foam ev battery gasket

Gaskets and Seals are needed to protect battery enclosures from potential damage caused by the elements and road debris.  CGR Products die cuts a variety of materials for enclosure gaskets that protect batteries from the elements while allowing items to be serviced over the life of the battery.

Silicone and Urethane foams are commonly used to seal out dirt and fluids while also helping to isolate vibrations.  Like other enclosures, EV battery enclosures also undergo temperature and pressure changes that make it important for ingress protection gaskets to perform flawlessly for the battery’s lifetime.

 

Venting Membranes

EV batteries present unique venting challenges including potentially dangerous thermal runaway conditions.  If lithium-ion battery cells are damaged, this can trigger other cells to decompose, leading to a thermal runaway condition and a potentially harmful scenario.  Die cut venting membranes are used for these applications.  An ePTFE venting membrane allows for enhanced heat and air ventilation, while burst vents enable quick evaluation of heat and pressure.  These are critical to all thermal runaway protection systems.

CGR Products and EV Batteries

Urethane foam ev battery gasketCGR Products will work with you during the early stages of your project to high level production volumes. We have a vast network of preferred suppliers and manufacturers with expert advice in making the right material selection.  We have 4 locations in the USA with over 190,000 sq ft of manufacturing space and are premier converters of foams, films, rubber, insulation, lamination, and more.

Feel free to contact us today about your upcoming EV Battery die cut applications.

 

Just a few of our EV Battery material suppliers

A World Class Converter

CGR Products is a world class converter of gaskets, seals, and die cut parts with 4 locations to serve you.  We have a history of providing performance enhancing and cost savings solutions for our customers.

What We Do:

CGR Products transforms raw materials into high-quality gaskets, seals, rings, and other engineered parts. We use a variety of cutting and fabricating capabilities to supply OEM customers in multiple markets.

about CGR Products

Why CGR?

  • Our complete in-house tool and die capabilities shorten lead times substantially. Dies are produced from AutoCAD drawings and tool maintenance is completed internally. CGR maintains an extensive inventory of raw materials that contributes to shorter delivery times for any size production runs.
  • An inventory of finished goods is stocked for customers who require JIT deliveries, or who simply need the peace of mind that a safety stock is in place. In addition, CGR provides customized VMI programs to multiple customers and is willing to create a program that can fit any customer’s unique requirements.
  • With facilities in four locations across the country, CGR can help reduce shipping costs and get parts to our customers faster.

4 Locations:

CGR Products operates in North Carolina, Alabama, Minnesota,  and Wisconsin with 140 employees and over 190,000 square feet of manufacturing, office, and warehouse space. All four facilities are ISO 9001:2015 Quality Standard and have a number of product platforms that meet stringent TS 16949 requirements. Operators use over 100 pieces of quality equipment to handle jobs efficiently and with precision.

CGR Locations

Learn More

Consider CGR Products for your next die cut project.  With over 190,000 square feet of manufacturing and warehouse space and over 100 top-quality machines, CGR serves a diverse range of clients with efficiency.

To request a quote for your next gasket, click Here or if you have a general question, Contact Us today.

Why is Being “Wrong” so Important?

Let’s face it, nobody likes to be wrong about anything.  It challenges your sense of self confidence, it’s embarrassing, and it just doesn’t feel good.

That said, being wrong is where learning takes place. When people are correct, they move to the next thing. There is no need for reflection or thinking. Being wrong forces people to contemplate their position and how they arrived at their decision. In doing this people see things differently and learn how to make better decisions. That part of being wrong is obvious, but there is much more to it.

Impacts

The impact on human interactions when people are wrong is monumental. Almost anyone that realizes they are wrong becomes defensive.  In that moment communication can deteriorate and in many cases that makes reaching a resolution difficult, if not impossible.  On the other hand, when someone needs to point out that another person is incorrect for some reason, it likely causes anxiety for the person that needs to explain why.  In a team structure, it can create stress and make it difficult for the team to function at a high level. We have all experienced situations where people go to great lengths to “prove” they are correct. There are two reasons people decide to press their position; they believe they are correct, or they do not want to lose.  Regardless of the reason, this activity is usually destructive for your relationships and your ability to function effectively in your role. No matter which reason is behind pushing that you are correct, at that moment pressing ahead is not going to help resolve anything. When there is disagreement, it is best to do nothing more than listen.

So, what are the not so obvious reasons why it is important to be wrong and accept it gracefully? Other people will analyze how you react to being wrong and how they interpret that will go a long way to determine what they think of you. When you accept that you are incorrect professionally, that shows them that you have confidence in yourself. At that moment they become more confident in you. At the same time, it makes it much easier for people to interact with you.  They are not afraid to point out your inaccuracies. In other words, you have given them permission to challenge you. People will be more candid and that will create more fruitful conversations and better decisions in your relationships and in team environments.

Picking your Battles

Let me take this to another level and suggest that at times you should go out of your way to say you are wrong even when you are not. I know that sounds strange but hear me out. You need to decide if you gain more by “not being right”. Human emotions are a powerful thing and in many cases winning the emotional war is more important than winning the immediate battle on an issue or topic. There are many interactions where it simply does not matter who is right. If someone thinks a car is gray and I think it’s silver, does it matter at all who is correct? For that matter, whether a car is blue or red doesn’t matter. As you know this is called picking your battles. Furthermore, if there is more than one way to solve a problem, it can be better in the long run to “not be right”, or probably more accurately, not insisting to do it your way, even if their way is not as good as yours in your opinion.  It helps people learn to solve problems and it makes them feel good which is a positive for everyone involved. No matter what role you are in, a spouse, a colleague, or a leader, productive resolutions to important issues are critical.  Being right or doing things your way in many cases will do nothing to solve problems because of the “collateral” damage that can occur.

Now you are asking, did Chuck really write this? Okay, do as I say, not as I do. I realize that this is a struggle for me and possibly others, but I hope you will at least give me credit for acknowledging that and putting this on paper (or on the computer screen).

Finally, I want to thank all our constituents, our wonderful Associates, our paying Customers, and our Supplier partners. It has been a trying year in many ways, but it is years like this that make us appreciate the not so trying years. Have a safe and enjoyable holiday season.

Chuck Keeley

President

CGR Products

Ingress Protection for Electrical Enclosures

Since CGR Products’ founding in 1963, we’ve worked with design engineers to bring projects to life, and we do everything we can to make that process efficient, affordable and successful. CGR uses a wide variety of converting methods and equipment to create parts and designs with precision and efficiency

Enclosure Protection

Enclosure gaskets are mechanical parts used to provide weatherproof seals on electrical enclosures and its doors. The typical method of attaching the gaskets is by means of a chemical fastener such as pressure sensitive adhesives (PSA). The mating surfaces many times can be irregular. In order to protect the sensitive electronic equipment inside the enclosure, a properly selected and manufactured gasket is critical. The enclosures can be used indoors or outdoors; therefore, a properly selected material and design are essential to ensure proper performance and long life. Generally, gaskets are used to seal out dust, dirt, water, Electromagnetic Interference (EMI), and Radio Frequency (RFI). Gaskets can also be used to dissipate vibration.

Industry Testing

Water: Direct spray tests are conducted. These tests can be a drip test, pressure hose test, or submersion test. UL requires that no water enter the unit during any of these tests. Full submersion tests can require up to 24 hours of submersion with zero entry of moisture.
Oil Swell: The gasket material is submerged in oil for 24 hours. The gasket material cannot swell over 25% of its original dimension or shrink more than 1%.
Tensile & Elongation: Some NEMA tests require tensile and elongation retention. For tensile and elongation the gasket materials are aged for 1 week @ 70 degrees C (158 F). After completion, the new and aged gasket materials are compared. To pass the tensile test the aged gasket material must stretch 75% of the same length as the new material before breaking. Elongation requires that the amount of force needed to break the aged material must be at least 75% of the new material.
Other tests include water absorption, compression deflection, and compression set. Contact CGR Products for a more detailed explanation for all of these industry tests.

 

For a FREE downloadable PDF version to keep for your records:

Download the full version of Ingress Protection for Electrical Enclosures here

 

Gasket Design

Die Cut Gaskets:
Die cutting is the general process of using a die or tooling to shear webs of low-strength materials, such as rubber, fiber, foam, paper, paper, plastics, thin metals, and pressure-sensitive adhesive tapes.

Die cutting can produce a precise shape with no seams. These gaskets form around the entire perimeter of the enclosure or the sealing surface. These type of gaskets can be supplied individually, in sheets, kiss-cut on rolls, or in strips, with or without pressure sensitive adhesives for mounting.

Strip Gasketing:
This method is the oldest. Supplied in rolls, the manufacturers of the enclosures adhere strips of the gasket material to the enclosure surface to be sealed. One side of the gasket material will have a pressure sensitive adhesive designed to adhere to the enclosure structure. The corners are not sealed due to the strip design. This method is the most economical but the corners are areas of concern for some applications.

 

Fold- out / Dovetail Gasket
In instances of very large enclosures, high volumes, or the design does not allow for strip gaskets, a fold-out or dovetail gasket may be an option. The fold-out gasket allows the die cut to be expanded to its final shape, eliminating the center scrap. A dovetail gasket works in a similar fashion, except the corners are mitered and fit together comparable to a jigsaw puzzle. The design of the enclosure and level of ingress protection needed will determine if this type of gasket is suitable.

 

Material Selection

Elastomeric materials are the most common and affordable materials used for enclosure gaskets and seals. These materials are available in foams, sponge, foam blends, and cork blends, with and without pressure sensitive adhesives. The key to choosing a gasket material is defining the environment in which it must perform. One must consider temperature / thermal management requirements, UV and Ozone exposure, EMI / RFI resistance, just to name a few.

What can CGR Products do for you?
CGR Products can assist in suggesting a material for an electrical enclosure. We have worked with many enclosure manufactures over the last 50 years. The full CGR Resource Library and team of experts are available to clients with specifications, cost charts, comparative material information and more. Our design team works with automotive, marine, appliance, plastic molding, power tool, electrical, small engine and countless other clients.

Our in-house tool and die capabilities mean maximum problem solving with minimal lead times, and an extensive inventory of raw materials supports projects of all kinds. Safety stocks are in place with our inventory of raw materials, and consultation with our experienced staff is always available to get you started.

 

For a FREE downloadable PDF version to keep for your records:

Download the full version of Ingress Protection for Electrical Enclosures here

 

Learn More

Consider CGR Products when you are developing your enclosure protection.  With over 170,000 square feet of manufacturing and warehouse space and over 100 top-quality machines, CGR serves a diverse range of clients, including those in the electrical enclosure industry.

To request a quote for your next gasket click Here or visit our Sample Gallery to view a portfolio encompassing all the industries we serve.

 

Learn About CGR Products Laminating Services

At CGR Products, we laminate many different materials on a daily basis.  We can laminate materials up to 84″ wide and as thin as .062″.  Materials can range from closed cell foam to heavy fabrics.  In this series, we will look at some common ways CGR Products offers laminating services.

Heat Platen Laminating

This type lamination involves a process where the adhesive roll rides over a heated platen.  Heat is used to soften the adhesive which is typically called “Flow”.   The heat of the platen is computer controlled and is critical to the speed of the process.   The material being laminated is pulled through the machine via driven rollers and the adhesive is applied to the bottom side of the substrate.  The bond of adhesive to the substrate is performed at the nip roller.  Once bonded the materials can be rewound and supplied on a core.

Watch our video below of closed cell foam being laminated with 3M9495 double coated adhesive.

Infrared Laminating

Infrared laminating is similar to heat platen laminating other than the heat source.  This process uses Infrared heat to help the adhesive flow before it is applied to the material.  One benefit of infrared is the heat can be micro adjusted while in process which allows the operator to quickly find the optimum temperature to create the best bond.  The infrared process is instant so the heat can be started and stopped within seconds saving valuable time and material.

Camouflage fabric laminated to closed cell sponge rubber

Camouflage fabric laminated to closed cell sponge rubber

Hot Roll Laminating

Hot Roll lamination involves applying adhesive over a heated drum.  The heated drum helps the adhesive flow just before being applied to the substrate. CGR Products hot roll laminator will handle materials up to 84″ wide.  Our hot roll laminator is well suited for materials such as carpet and textiles.  A common use for this machine is the process of glue web lamination.  This process allows customers to reactivate the adhesive with heat when parts are ready to be installed.

Rotary Laminating

For high volume die cutting applications, we utilize Rotary lamination.  We commonly laminate materials up to 16″ wide such as 3M VHB, Copper foils, and Mylar.   Depending on the complexity of the part,  we can usually laminate and cut the part in one pass.  This helps to reduce cost and increase responsiveness to your customer.

Learn More

To learn more about our lamination capabilities, visit our laminating services page.   Feel free to click around our website or visit our Sample Gallery to view a portfolio encompassing many of the industries we serve.

Gap Fillers for Acoustical and Ingress Protection

Elastomeric gap fillers come in many shapes and sizes,  from open cell foam used for acoustical management, to closed cell sponge used for sealing outside elements. In this article, we will discuss three types of gap fillers that CGR Products manufactures on a daily basis.

Open Cell Polyurethane

Open cell polyurethane is a great low cost material as a gap filler when sealing out water is not applicable.  Open cell foam is made up of cells that are intentionally left open, which results in foam that is softer and more flexible.  Its composition allows air and moisture to pass through so that when condensation takes place, the foam dries and doesn’t hold the moisture.

Open cell polyurethane works well for items such as bulldozers, excavators, generators, and other heavy equipment that have engines that generate a significant amount of noise.  Polyurethane foam gap fillers can help reduce engine noise and other acoustical noises when water ingress is not an issue.

Open cell polyurethane from CGR Products is available with or without adhesive on one side.  This material can be die cut into any shape used for a specific area or supplied in roll form.  Thickness typically ranges from .125″ to 1.25″.  We utilize an acrylic adhesive on our polyurethane foam for optimal long-term, durable applications.

Closed Cell Foam

Closed cell foam is made of cells that are fully closed and packed tightly together. This results in foam that is more rigid and stable than open cell foam.  Closed cell foam can block air movement and water ingress.  Due to the cell composition, closed cell foam is typically much denser than open cell foam.

Closed cell foam rubber can fill large voids and gaps, and also has cushioning properties to help lessen impact between two substrates. Closed cell foam is perfect for sealing gaps and helps reduce ingress, whereas open cell foam offers more flexibility.  Additionally, closed cell foam is ideal for outdoor applications because it resists weathering, UV rays, and fungi.

At CGR Products, we offer a variety of adhesive options for closed cell foam gap fillers. From economical “aid in assembly” applications to higher performance permanent bonding applications.  We can die cut these fillers into individual parts or they can be supplied in continuous rolls.  We skive our thickness in house to accommodate our customers exact specifications.

Crushed Semi-Closed Cell Foam

Crushed semi-closed foam is great for filling uneven gaps and sealing out acoustics, dust, heat, and air.  Semi-closed cell foam is a soft, flexible foam. It has good UV resistance and good resistance to ozone and weathering, making it an ideal material for both indoor and outdoor use. This soft, compressible closed-cell foam, can fill various types of gaps, impede heat, water, sound, and vibration, offering a solution for various uneven types of gap filler applications.  Semi-closed cell materials combine the flexibility of open cell materials with the excellent sealing capabilities of closed cell foams.armacell-ensolite-foam

As with our closed cell foams, CGR Products offer a variety of adhesive options for semi-closed cell foam gap fillers.  We offer die cutting, and various types of fabrication, such as layering and bonding different types of foams.  An example of a layered gap filler is a closed cell foam on the bottom for rigidity and support, bonded with a crushed foam on the top for compression and uneven surfaces.  Crushed semi-closed cell gap fillers can be die cut to meet specific sizes or supplied in roll form.

Learn More

Consider CGR Products when you are developing gap fillers for sound and ingress protection.  With over 170,000 square feet of manufacturing and warehouse space and over 100 top-quality machines, CGR serves a diverse range of clients, including those in the heavy equipment industry. To learn more about our capabilities visit our Die Cutting pages or visit our Open and Closed Cell Foam pages to view a portfolio of the different types of foam we work with.

Noise, Vibration, and Harshness (NVH): What You Need to Know

Guest Author: Technicon Acoustics

Noise, Vibration, and Harshness (NVH) is a concern for many companies.  One of our long time suppliers Technicon Acoustics has provided the below resource and also has a full version pdf available to download here.

The extraneous sound and vibration are more than just an annoyance for people who work around noisy machinery. Excess equipment noise creates a perception of low quality that can decrease the perceived value of an OEM’s productNoise and vibration are first and foremost bothersome, but it can also cause underlying issues of increased wear and tear, ultimately leading to shorter equipment life. These results have detrimental effects on the marketability of the productdecreasing its appeal to the customer. 

Fortunately, there are methods to decrease excessive noise and vibration to optimize performance and enhance the overall consensus of your product. 

What is the Meaning of NVH? 

NVH stands for “Noise, Vibration, and Harshness.” NVH seeks to understand the source of industrial noise and modify equipment to reduce it. When looking for methods to diminish the noise and vibration from machinery, Technicon Acoustics relies on these core principles when engaging in equipment modification:  

  • Reducing the source strength 
  • Interrupting the path of the noise and vibration 
  • Absorbing the noise and vibration 
  • Smoothing out sound quality and annoying tones 
  • Increasing speech intelligibility inside of the machinery 

Sound waves move outward from their source at different strengths and speeds, depending upon the mediums they encounter. Installing the right kind of barrier material deflects sound waves, reducing their impact. Some mediums absorb sound waves rather than allowing them to proliferate. Specialized foams are often used to absorb sound waves caused by vibrations.  

The field of NVH has its roots in the automotive industry. Sound dampening methods were originally developed to reduce the noise produced by automobiles, but now noise and vibration control techniques are applied across an array of industries. 

Engines and motors on machines and vehicles are the primary sources of noise in an industrial setting. Interrupting the path of the noise involves installing barriers within the machinery, as well as equipping individual components that are prone to vibration with damping material that reduces vibrations. By addressing both structure-borne and airborne noise the overall sound quality of the machinery improves. In turn, this improves the ability of operators or passengers to understand one another or to hear the speech from a GPS or radio. This is the definition of speech intelligibility. 

Increasing Sound Quality and Speech Intelligibility 

Not all sound is created equal. The different sounds and their harshness all have a unique perception to the individual. Some noises may sound alike, but have certain attributes which make it more disturbing. A tone is defined as any frequency bin that has a dB rating of +/- 3dB from the previous bin, which makes the difference audible and annoying to the human ear. There are methods to reduce noise and vibration, but masking the harshness of the noise needs to be accounted for as well. 

By properly addressing the noise sourcesthe acoustic signature becomes less harsh. No one wants to be in or around a piece of equipment that has a loud annoying tone to it – whining, thumping, scraping, etc. Improving the sound quality of a machine and smoothing out the annoying tones helps improve speech intelligibility, which is vital inside cabs or simply being around the equipment. 

In an ever-growing world of digital communication, speech intelligibility is not just important for persontoperson interaction. Devices also need to be able to understand voice commands that are given by the operators and vice versa.  

Why is Measuring NVH Important? 

Measuring NVH and implementing the correct acoustic solutions will enhance the value of your product. Customers commonly look for the equipment and machinery that check all the boxes on their shortlist, which always includes a product with the least amount of excessive noise, vibration, and harshness.  

With vehicles, noise originates in the powertrain, which includes the motor, engine, exhaust, and all ancillary support systems. At lower speeds, powertrain noise is the most noticeable type of sound. At higher speedsthose exceeding 100 km per hour—rolling noise takes over. Rolling noise is directly tied to airflow. An everyday example of this would be to compare the noise generated by a car in city traffic compared with the noise generated on the highway.  

Vibration is caused by the sound waves generated by moving components within the equipment or vehicle. As sound waves emanate from their source, they reverberate off of other components and cause them to vibrate as well.  

When it comes to perceptible sound, the human ear has a wide range. We are able to sense anywhere between 20-20,000 Hz. It is critical for engineers and manufacturers to reduce the upper threshold of their equipment’s NVH sources during the design process to appropriately mitigate risks posed by industrial noise. 

Lowering NVH Levels with Technicon Acoustics 

When dealing with sources of NVH, there are two types of sounds that need to be considered:  

  • Structure-borne 
  • Airborne 

Structure-borne sound results from all moving components within the machinery. Airborne sound is generated by the equipment’s aerodynamics and combustion processes and is transmitted directly to your ear. Together, these two types of sound compose the machinery’s overall acoustics.   

Technicon Acoustics uses different solutions to reduce harmful noise. Designed to address the three core NVH principles, these solutions include: 

  • Acoustic absorbers 
  • Acoustic barriers 
  • Damping materials 

Acoustic absorbers are made using porous materials like polyester foam and polyester fiber. These absorbers are installed on sound-reflective surfaces to prevent airborne noise from proliferating and affecting equipment operators and bystanders.  

Acoustic barriers are made from massloaded vinyl, a dense material that stops sound waves from spreading. Barriers serve as an environmental modification and are often installed on surfaces surrounding industrial machinery or in the cab of a vehicle.  

Certain materials actually amplify the frequency and harshness of sound waves. Damping materials such as PVC and foam composites dissipate sound waves before they amplify and are used to keep the interiors of large-scale mass transit vehicles comfortable for passengers.   

Click here to download the full NVH materials guide PDF.

CGR Products has worked with Technicon foams for well over 30 years, providing solutions ranging from small gap fillers to full enclosure panels.  As flexible material specialists, the CGR Products team offers years of experience in converting foam materials into gaskets and components. Our in-house precision cutting services include rotary, flatbed,  kiss cutting, slitting, waterjet, knife cutting, and more.

Speaker Gaskets for OEM Manufacturers

CGR Products works with many manufacturers die cutting speaker gaskets.  Our gaskets are used in several markets including, marine speakers, automotive speakers, home speakers, and more.  Our die cutting capabilities allow us to cut virtually any size and pattern for large volume applications.  This article will describe a variety or materials and cutting methods used to produce speaker gaskets.

Materials

CGR Products stocks several raw materials used for speaker gaskets.  Materials such as closed cell sponge, cross linked polyethylene, and urethane foam are commonly used.  Closed cell sponge is the most common material used by speaker manufacturers. In the case of rear mounted speakers, a material such as closed cell sponge, or cross linked polyethylene (XLPE) is highly desired to make an airtight seal.  Later in the speakers life, if rear mounted, the speaker can easily be removed with no damage to the enclosure.

For conventional speaker mounting, the gasket is used to make a seal to a mounting ring, or to give the speaker better esthetics.  Material such as closed cell foam or urethane foams is typical for these applications.

Die cut gaskets from the above-mentioned materials allow for an easy installation.  CGR Products die cuts gasketsfrom all of these materials plain, or with adhesive. Materials laminated with adhesive on one side provide an easy installation by the OEM.  The gaskets will have a removable liner on the mating side, allowing for a quick peel and stick application.

CGR Products die cuts dampening or batting material for all types of speaker enclosures.  Typically, this material is either a non woven polyester batting or 2lb open cell urethane foam.  Depending on the cabinet design, we will die cut panels for the whole cabinet, or critical pads that are mounted strategically for dampening.  The dampening is critical in automotive applications to keep rattles and vibrations to a minimum.  These materials can also be laminated with adhesive if desired.  With polyester batting, CGR can add a heat activated glue web.  Urethane foam can have adhesive with a removable liner for peel and stick application.

 

Die Cut Gasket

CGR Products can die-cut products up to 75″ wide x 84″ long in a single stroke. For segmented parts, we can incorporate “dovetailed” or interlocking parts.  For supplying high volumes of speaker gaskets, this method of die cutting is the most desired for cost savings.  CGR Products will design the stamping tool to allow for the best material savings plus maximize throughput to reduce cost.  Cutting high volumes of parts are what we do best and set us apart from our competitors. Our large format cutting operation has its own dedicated shipping dock with 7 bays.

CGR Products also uses a variety of waterjet machines for cutting speaker gaskets.  Waterjet cutting offers excellent material yield and the ability to cut a multitude of materials. The CGR waterjets require no tooling or tool maintenance, lowering your initial set up charge.  We use custom made waterjet machines with multiple cutting heads to allow for multiple cuts at the same time.

 

Knife cutting is another exceptional option for fabrication tasks that require precision cutting without the use of waterjet machinery. Our state-of-the-art knife cutting machinery utilizes a serrated (dentated or toothed) blade in the Z-axis. This ensures the production of a precise end product, every time, no matter how intricate the details. The machine is powered by advanced control software and a powerful, versatile cutting head.  CGR’s knife cutting machine eliminates the need for cutting dies and increases yields to enable quick turnaround and higher precision.

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CGR Products is capable of producing custom speaker gaskets for a variety of applications.  With over 170,000 square feet of manufacturing and warehouse space and over 100 top-quality machines, CGR serves a diverse range of clients, including those in the speaker industry.  To learn more about how CGR Products can help with your die cut speaker gaskets, Contact Us today. Ready to get started,  Request a Quote for your die cut parts.