Cell rubber gaskets, PE foam profiles & special products
windowSafe® sealing gaskets
We use different materials to manufacture standard gaskets and customized products (for example cellular rubber, sponge rubber, EPDM soft rubber and many more). Thanks to a wide range of manufacturing methods almost every outline and quantity is practicable. Often without tool costs so even small or initial batches can be provided without additional costs.
windowSafe® extrudes PE foam profiles
Polyethylene foam is a closed-cell material with excellent chemical and physical properties. Profiles made of cell polyethylene provide very high thermal insulation and are thus of great import when it comes to energetically sustainable building.
>> more about extruded PE foam profiles
windowSafe® cell rubber & other profiles
From A(ngle shaped) to U(-shaped) – we’ll find the best solution for you: whether you need a standard product (which can usually be provided without tool costs) or a customized solution that fits a special purpose, e.g. high temperature resistance.
>> more about cell rubber and other profiles
windowSafe® special gaskets & additional products
In this section we provide special solutions: from prototyping and surface coating to gaskets and other products made of nonstandard materials.
To provide the optimal product solution there is a wide range of manufacturing techniques that can be applied. A lot of products also require a combination of processes. Long-term experiences in the gasket and profile sector enable our experts to find suitable manufacturing techniques for our customer’s demands.
A lot of materials have to be split into sheets of optimal thickness before the actual manufacturing starts. For example: a cellular rubber block with the dimensions 1.000 x 1.000 mm and a thickness of 40 mm can be split into 4 thinner sheets with the dimensions 1.000 x 1.000 x 10 mm. Because of the varying thickness of products splitting is one of the most common production processes when it comes to rubber.
>> Water jet cutting
In this process the material is cut into the desired shape by a water jet using very high pressure. Thus the material doesn’t heat up and there is no need for tools. Even complex shapes can be manufactured quickly and easily. Compared to die cut parts gaskets cut by water jet have straight edges but can show groove marks due to the special characteristics of the water jet.
>> Die cutting
Rubber products are often cut using metal dies. The dies are punched through the material and cut out parts of the desired shape. Compared to water jet cut items the edges of die cut parts are smooth but can be slightly concave if the material exceeds a certain thickness. A very common special form of die cutting is the so-called kiss cut technique. In this process the material is first laminated with an adhesive. Afterwards the material is punched without cutting through the attached adhesive carrier material. Because peeling kiss cut parts off an adhesive paper is considerably easier than removing the adhesive material from an individual part this form of die cutting is well-established.
If the basic material can’t provide the required dimensions for the final product gluing is often the method of choice. E.g. for a cell rubber gasket with the thickness of 70 mm two sheets of 35 mm thickness have to be glued together first. Then the gasket is cut out of the new 70 mm sheet.
>> Welding / laminating
Welding is a useful alternative to gluing but can only be applied to thermoplastic materials such as polyethylene. In this process heat and pressure are used to bond sheets or blocks of material or to make compounds of various materials or colors. There are no foreign substances used and the foam maintains its original appearance.
When it comes to elastomers and cell polyethylene adhesives are the most common form of coating. Usually pressure or heat is used to apply the coating to the material. Practically all elastomer types: cell rubber, sponge rubber, soft rubber but also cell polyethylene and other materials can be coated with adhesives. In the sealing sector adhesive coating is often used as assembling aid.
Extrusion involves viscous materials that are being pressed continuously through a die which has the shape of the final product. Extrusion processes are usually employed for the manufacturing of profiles using sponge rubber, soft rubber, silicone, PVC or TPE. A special technique is applied during the production of cell polyethylene profiles. Here a foaming agent is added to the extrusion process that expands the material directly after pressing it through the die. To regulate the expansion to the desired amount takes a lot of knowhow and experience especially in chosing the right raw material mixture as well as in manufacturing the die.