A wide variety of sealing solutions are used throughout today’s passenger cars. These include O-Rings that withstand high pressures in shock absorbers, sophisticated gaskets in electronic control units (ECUs), safety critical custom-molded components in braking systems and seals that withstand extreme temperatures, pressures and aggressive media in fuel injectors.
Trelleborg Sealing Solutions continuously develops its specially designed seals to meet the most challenging needs of today's OEM's and their component suppliers.
In a proprietary co-injection process, a technical thermoplastic and a silicone are formed into a fully bonded high-precision composite, creating the 2-component part. This fully automated process makes Trelleborg Sealing Solutions a market leader in Liquid Silicone Rubber (LSR) injection molding and 2-shot processing capabilities. If requested, 2-Component parts can be produced in state-of-the-art cleanrooms which offer completely flashless parts for use within safety critical applications.
Automotive trends affecting liquid silicone rubber (LSR) injection molding
Benefits of 2-Component part solutions
2-Component solutions with LSR
Thermoplastic in combination with LSR
LSR co-injection or over-molding with a select range of technical thermoplastic substrates such as:
LSR in combination with LSR
Co-injection or Overmolding of dissimilar types of silicone into composite parts with varying properties such as:
Lighter Vehicles From the Inside Out
Current manufacturing techniques at Trelleborg Sealing Solutions were specifically developed over 30 years ago to help companies overcome the limitations of traditional materials and enable new capabilities for critical parts. Within the automotive sector, many of these parts are already being converted to lightweight fiber-reinforced composites, gaining significant performance benefits while also reducing weight. We are bringing these advantages of automotive composites to unforeseen heights.
With industry-leading expertise in the automated additive manufacturing of thermoplastic composites, we are working with leading manufacturers to create parts for real-world applications that also allow for scalable processing.
Using Automated Fiber Placement (AFP) technology and Trelleborg know-how, we are creating recyclable parts with the lightest weight, greatest fatigue resistance, highest vibration dampening, and best damage tolerance available. By entering the automotive market, we have demonstrated that high-performance parts can be realized even in an industry often requiring high-volume production. In-situ (on-the-fly) manufacturing, high-speed throughput (with our laser heating system), and an additive manufacturing process remove the need for post processing steps. Moreover, we enable residual advantages for the:
Working with our engineering teams, Trelleborg Sealing Solutions will support you in the development of customized engineered molded parts designed to suit your individual needs.
This may be a flat gasket of any dimension or a seal of complex geometry that may consolidate a number of products into one.
Our specially designed sealing solutions can provide significant benefits from a cost, function, manufacturing or performance perspective, providing you with a real competitive advantage.
Specially Engineered Gasket
ECU housing seals are specially designed to protect electronic components by sealing out transmission oil.
Highlights: The electrical flat ribbon cables are safely sealed from aggressive media
ECU Housing Gasket
ECU housing gaskets are specially designed for the given application situation and limits (requirements, maximal forces).
Highlights: Resistance to a range of different transmission oils, as well as special requirements for smoothness and cleanliness.
Manufactured to meet the needs of electric vehicle manufacturers, HiSpin® rotary seals are specifically engineered for use in next-generation e-axles. A major technology in electric cars, e-axles combine the electric motor and gearbox in a single unit, which poses several unique sealing requirements:
HiSpin® rotary seals deliver optimum performance at high rotational speeds under extreme temperature and lubrication conditions:
The L-Cup® is a single acting asymmetrical rod seal for a wide spectrum of applications.
The FEA optimized design provides outstanding sealing effectiveness and an improved hydrodynamic back pumping effect.
These features are made possible through minimized friction and reduced wear and tear in comparison to traditionally used lip seals.
O-Rings offer the designer an efficient and economical sealing element for a wide range of static and dynamic applications.
The large selection of elastomer materials for both standard and special applications, allow the O-Ring to seal practically all liquid and gaseous media.
Specially developed radial seals that compensate for a wide range of tolerances. Innovative packaging with 3D printing technology is possible and ensures safe transport globally and speed up the manufacturing process in high volume productions.
Transmission control unit
PTFE based seals are always used if friction, media resistance, and space is an issue. Our Turcon®-PTFE materials, possess a very low friction coefficient and simultaneously a good shape stability against high pressures. They are the ideal materials to design a low friction seal which works with high pressures, minimal space and has a high media resistant. As PTFE does not have an elastomer-elasticity, these kinds of seals are actuated by an O-ring. The O-ring gives the needed elasticity to compensate for misalignment. All of the rod seals have a back pumping effect which enables the seal to bring eventual leakage back to the pressure chamber against the system pressure.
Learn more about some of our patented Turcon Seals
Rubore® Seals are produced through an advanced technology process which creates a sandwich composite material combining rubber, PTFE and metal layers.
Reduces weight:The dimensional stability of Rubore® Seals allows for the design of thinner metal walls which leads to significant weight reductions when compared to full elastomer seals.
Lower handling costs:The stiffness of Rubore® Seals saves assembly time and lessens logistic requirements, lowering overall manufacturing costs.
Compensates for roughness: The Rubore® technology is an effective way to cope with uneven surfaces and pinholes on metal parts. This eliminates the need for surface finishing and significantly reduces process steps and costs.
Easy Assembly: Assembly speed is increased and made easier through the stiffening of the elastomer component by the metal layer.
More information on our Rubore Products
Shims / Insulators
A unique rubber to metal composite material designed to solve noise and vibration problems.
Trelleborg Sealing Solutions Kalmar manufactures a wide range of noise damping shims / insulators that are used when endurance against thermal, chemical and mechanical stress is required. This is combined with out-standing sound damping, sealing, vibration insulation, compressibility and bonding capacity.
The materials consist of different combinations of layers of rubber, carbon steel, stainless steel, fibre glass, cold pressure adhesives, acrylic or silicone based and hot sensitive glues.
Shims / Insulators
Our unique rubber to metal composite materials for noise damping in disc brakes combine a number of valuable properties: vibration insulation, compressibility and excellent adhesion. The rubber composite materials are excellent for applications with demanding insulation for vibration and noise. The materials retain their integrity even when subjected to high pressure and high temperature.
Noise damping components in brakes have to endure enormous strains and tension - extreme temperature, mechanical stress, salt, water, oil etc… Testing one and the same brake system in mountain and desert country, as well as in urban traffic and on the open highway is a costly and time consuming process.
We simplify this process by running tests in our fully computerized brake-noise dynamometers, equipped with unique acclimatiser. This allows us to literally test a brake in any climate in the world.
The Skirted Piston, also known as Banded Piston, plays an important role in automotive shock absorbers. For optimal performance it must operate with low friction, high side-load capacity, wear resistance and reliable sealing.
Material and Design
Understanding the needs of automotive manufacturers, Trelleborg Sealing Solutions can offer Skirted Piston solutions custom-designed to a wide range of requirements with rapid turnaround times. This includes a size range of 25 to 50 mm and both single or double lip configurations. To note that the metal pistons are to be supplied by the customer, either with an existing groove profile or according to our recommendations.
Skirted Piston discs are manufactured from world-renowned Turcon® polytetrafluoroethylene (PTFE) based material, specially formulated and proven for use in Skirted Piston applications..
Production Solution Provider
Uniquely positioned to offer service with a global network and local support, Trelleborg Sealing Solutions can provide a range of different production options giving customers assembly and purchasing savings, increased product reliability and optimized supply chains. Lower volumes can be handled by us on in-house developed machines, while for higher volumes these machines can also be supplied to the customer.
The Turcon®Glyd Ring® T is a double acting symmetrical seal which differs from a standard Glyd Ring® due to its trapezoidal cross section and concave edges. This improved design permits a specific tilting of the seal to ensure that the maximum compression is always applied on the areas with the highest pressure, thereby providing an optimal solution for leakage control.
On areas of low pressure, there is no compression or shear loads on the seal. This, together with the concave shape of the seal, enables a higher radial clearance and reduces the danger of gap extrusion. In addition, the Turcon®Glyd Ring®T provides excellent friction characteristics, no stick-slip and minimal break out force.
Extended Seal Life and Low Friction
The Turcon® Roto L seal is the first ever active seal and is engineered to extend seal life on axle systems. Uniquely, it only seals when sealing is required. This reduces friction to lower fuel consumption and thereby conserves energy. It is ideal for sealing in drivetrain applications, such as the Central Tire Inflation Systems (CTIS).
Turcon® Roto L combines a PTFE based sealing lip with a rubber jacket and a stable shape-forming metal part. The seal’s patented design ensures that, for the majority of the time, the sealing lip is held lightly against the sealing surface until pressure is activated. This unique design offers features and benefits that no other seal can.
Features and Benefits:
Less pressure, less friction
Turcon® Roto L reduces shaft run-in significantly. A standard radial oil seal has a run-in of 10.1 μm after 168 h. In comparison, the Turcon® Roto L has a run in of 4.59 μm after 780 h, resulting in a seal life that is at least four times longer than a standard radial oil seal.
Twin seals are high performance rod/piston seals with a PTFE profile used in dynamic hydraulic applications with pressures up to 200 bar.
In ride control applications , they are effective in reducing friction and extending seal life,thereby providing a no "stick-slip" effect, maximal performance, superior ride and damping functions.
The Valve seal is an optimized sealing element designed through FEM calculations for high pressure fuel pump applications. The Valve seal regulates the rate of the fuel flow.
High pressure fuel pump
Ventseal-Light combines a seal and pressure relief valve function all in one product. It is used for ventilation of locked containers such as an Absorbent Glass Mat (AGM) battery for start-stop technology, fluid reservoirs or sealed beam headlamp units.
We provide a wide range of advanced and customized solutions that seal, damp and protect. Our extensive material portfolio makes it possible to be material neutral, offering solutions that provide the exact functionality required. Our range of products includes:
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