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Tag Archive: automotive assembly

  1. Everything You Need To Know For Easy O-ring Installation

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    The O-ring…the little part that plays a big role!

    “What are the parts of a car?”  Most people will answer with “engine, thermostat, radiator, water pump, battery, alternator, ignition, steering wheel, tires, windows, doors, and seat belts”. Not too many people will mention O-rings. But, O-rings play an integral role in the manufacturing and operation of vehicles of all kinds, as well as most other everyday items such as appliances, pumps, and medical devices.

    What Are O-rings?

    An O-ring is “a loop of elastomer with a round cross-section, designed to be seated in a groove and compressed during assembly between two or more parts, creating a seal at the interface.” (https://en.wikipedia.org/wiki/O-ring). Like the name implies, an O-ring is a round, rubber ring. O-rings are used to create a tight seal between assembled parts to prevent fluids or air from passing from one part to another. The simple little O-ring is often one of the most important components in finished goods. Without properly installed O-rings leaks and product failures could occur.

    Common Installation Problems

    O-rings need to be properly installed to do their job and function properly. When installed correctly, O-rings can prevent leaks and add to the service life of the component. Incorrectly installed O-rings may cause leakage resulting in part damage, requiring taking apart and reassembling the component.  Some common problems that occur during O-ring installation include tears, twisting and turning, and overstretching.

    5 Guidelines for Installing O-rings

    Installing O-rings properly at the outset saves time and money in the long run. These installation tips can help you avoid problems that may cause application issues down the road.

    1. Size Matters: Use the right size O-ring for each unique assembly. O-rings that are too small are more prone to tearing and breakage. O-rings that are too large will not provide an adequate seal.
    2. Avoid Overstretching: Each O-ring has a maximum stretch point. Overstretching can cause O-rings to break or tear during assembly or use. Engineers need to ensure that the stretch does not go beyond the maximum elongation of the O-ring. It’s also important to stretch the O-ring evenly, not just on one side or the other. In general, try to stretch the O-ring as little as possible for a tighter fit.
    3. Slide, Don’t Roll: Rolling an O-ring down a shaft for installation leads to spiraling. Spiral wound O-rings cannot be properly installed and their functionality will be limited. This can result in leaks and/or damage to the finished assembly. Sliding the O-ring into place, rather than rolling it, helps avoid spiraling. Using a lubricant helps the O-ring slide easily into place.
    4. Ease O-rings Over Threads: O-rings are often mated with threaded parts. The threads can easily tear the rubber O-rings. Covering the threads with masking tape during installation and using an assembly lubricant can help protect the O-ring from nicks and tears.
    5. Keep Away From Sharp Edges: Some mated parts may also have sharp corners or edges that can damage O-rings. Sometimes these tears are so small they are not visible, resulting in leakage problems later on. Avoid forcing O-rings onto sharp corners and edges. Lubricating the O-rings makes it easier to slide them into place.

    Overall, it’s best to avoid using excess force while installing O-rings. Using an assembly lubricant helps ensure that many of the above problems are avoided.

    O-ring Lubricants

    Using a lubricant for O-ring assembly can prevent tears, twisting, pinching, cutting and abrasion of the rubber.  A thin film of lubricant applied to the O-ring fills in any gaps, holes, or spaces between the O-ring and the mated part, allowing them to slide across each other. By reducing the surface tension between the two surfaces, the O-ring can slide into place easily, providing a tight fit.

    Advantages of using assembly lubricants for O-ring installation include:
    • Reduce force needed for installation
    • Accelerate assembly processes
    • Achieve closer fits by helping to properly seat the O-ring
    • Aid automated assemblies
    • Improve product performance and reduce failures
    • Increase production rates
    • Help avoid worker injuries

    Types of O-ring Lubricants

    There are numerous types of lubricants that can be used to install O-rings. Some common choices include soap and water, petroleum distillates, solvents and ester based products. Many traditional choices may cause damage to the rubber O-ring or present safety concerns.

    For example, petroleum based products can cause rubber to swell or dry out. Solvents provide poor lubrication, contain high VOCs, may be flammable, and pose possible health risks. Soap and water, while safe, provides inconsistent, nominal lubrication and may reactivate when wet causing problems after assembly.

    Ester based lubricants are an ideal solution. They provide excellent reduction in friction, offer temporary lubrication, and are safe for both workers and the environment.

    Here is a comparison of some common lubricant choices:

    Lubricants Comparison Chart

    Reduction of Friction Chart

    So, how do you choose the right product? Consider these factors:

    The Perfect Solution

    P-80® Temporary Rubber Assembly Lubricants are an excellent choice for O-ring assembly. P-80® lubricants significantly reduce friction helping rubber parts slide easily into place. And, they do not contain any hazardous ingredients, making them safe for workers and the environment. P-80’s unique, water-based formula is temporary; once dry, P-80 stops lubricating and parts remain in place.

    O-ring installation without lubrication:

    O-ring installation using P-80:

    Installing O-rings doesn’t have to be a struggle. Remember, these small rubber parts can make or break the functionality of your finished assembly. Take the time to install them properly and use a temporary assembly lubricant to aid the process and protect the part.

    Contact International Products Corporation to learn more about using P-80 Rubber Lubricants for O-ring assembly.

    Have an O-ring you need to install? Request a free sample for testing

  2. Stop Struggling … See How Temporary Lubricants Make Rubber Assembly Easier!

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    Have you ever struggled with rubber assembly? If so, you’ve probably experienced for yourself the excessive force needed to properly install hoses, seals, gaskets, O-rings and many other rubber parts. Wouldn’t it be nice if someone came up with a better way?

    Your wishes have been granted! Temporary rubber assembly lubricants were developed specifically to solve this common problem. Temporary rubber lubricants can ease assembly processes and significantly reduce the force needed to assemble rubber parts.

    So, how effective are temporary assembly lubricants? Why not see for yourself? International Products Corporation (IPC), manufacturer of P-80® temporary rubber assembly lubricants, put together this short video showing the reduction in force obtained by using P-80® Emulsion to assemble a rubber hose.

    m90-wipe

    The results of this test are dramatic. A 63% reduction of force was achieved by using P-80 Emulsion for this assembly. A digital force gauge manufactured by Mecmesin was used for measurement. The amount of force needed to assemble a dry piece of hose was 196 Newtons. IPC’s test lab then lubricated the same hose with P-80 Emulsion and the amount of force needed for the same assembly dropped to 72 Newtons. That represents a reduction of force of 124 Newtons or 63%.

    What are some of the advantages of reducing the force required to install rubber parts?
    • Allow for tighter fitting part design
    • Improve product performance
    • Increase production rates by allowing for faster assembly
    • Reduce worker injuries by decreasing the assembly force required
    • Reduce part rejection

    The next time you’re having trouble with hoses, seals, gaskets, O-Rings or any other rubber part, remember to use a temporary rubber assembly lubricant and watch the parts slide into place with much less force. Temporary lubricants are ideal for rubber assembly because they reduce the friction needed to assemble parts.

    Want more information about temporary rubber assembly lubricants, including how to use them and factors to consider when choosing a lubricant? Contact IPC for help finding the best solution for your assembly needs.

  3. Hassled By Hose Assembly? P-80® Lubricants Can Help!

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    Rubber hoses are everywhere! Have you ever stopped to consider how many everyday items have hoses? Cars, trucks, buses, planes, boats, motorcycles, construction equipment, appliances, pumps, and medical equipment all contain hoses.

    So, what exactly is a hose? Hoses are flexible hollow tubes that transport fluids, or gases, from one location to another. It’s easy to see how hoses are an integral part of all of the items mentioned above. Hoses allow gas to travel from the fuel tank of your car to the engine, water to move from the water line in your home to the dispenser on your refrigerator, and medicine to flow through an IV unit.

    Most hoses are attached to other parts of an assembly by some type of connector, usually referred to as a coupling or a fitting. Hose fittings are typically made of metal or plastic. Anyone who has ever worked with rubber parts knows they can be difficult to assemble. Trying to install, remove or manipulate tight fitting rubber components can be a real challenge.

    Since hoses are so vital, it’s important to make sure they are assembled properly to avoid problems later on. Parts that are improperly aligned or installed may result in performance or safety issues. Hoses and couplings are designed with a tight fit so they stay together after assembly to function properly and avoid leakage. The insertion force needed to complete the assembly can be extreme, sometimes causing worker injury.

    So, how do you make hose assembly easier? P-80® temporary assembly lubricants can help! P-80 temporary rubber assembly lubricants significantly reduce friction to help rubber parts slide easily into place. P-80 lubricants are water-based, and do not contain alcohol or petroleum distillates so they will not cause rubber to dry out, swell or harden. P-80 does not contain silicon or other persistent ingredients, so once dry you have a tight fitting part.

    What are the advantages of using P-80 lubricants?
    • Reduce the force required for installation
    • Increase production rates
    • Reduce part breakage, leaks and rejects
    • Allow for closer fitting part design
    • Reduce risk of musculoskeletal and slippage related injuries

    What if my hoses undergo pressure testing immediately after assembly? P-80 lubricants provide temporary lubrication, once dry the lubrication ceases and parts stay in place. International Products Corporation (IPC) recommends using P-80® Grip-It for hose assemblies that are pressure tested or drop tested immediately after assembly. P-80 Grip-It provides the lubricity needed to complete your assembly and then dries quickly to allow the natural tight fit of rubber to return. When dry, P-80 Grip-it leaves a tacky finish to help parts stay in place, making it an excellent choice for use on pressure-tested hoses. Download our case study detailing how one major appliance manufacturer benefited from using P-80® Grip-It for dishwasher hose assembly to reduce drop test failures.

    In addition to Grip-It, P-80 is available in five additional water-based formulas, including two that are approved for use in incidental food contact applications. P-80 lubricants offer superior lubrication and are compatible with a variety of surfaces. They are environmentally friendly, most are biodegradable.

    Make hose assembly easier with P-80! Contact IPC’s technical team to help you find the best solution for your assembly needs.

  4. The Best Solution for Easy Automotive Rubber Assembly

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    There are an amazing number of rubber parts in a single automobile. It can be mindboggling to think of the various rubber components that are involved in the assembly of a car. O-rings, bushings, seals, hoses, engine mounts, belts, gaskets…any number of chassis, engine and suspension components are made of rubber or plastic. 

    Rubber is naturally slip resistant, making it difficult to work with at times. Trying to install, remove or manipulate tight fitting rubber components can be a real challenge. Parts that are improperly aligned or installed may result in performance or safety issues. Using a temporary assembly lubricant, like P-80®, makes rubber installation easier and helps to avoid these types of problems.

    P-80 temporary rubber assembly lubricants are designed to decrease the installation force needed to install rubber parts. P-80 lubricants enable rubber parts to slide easily into place with minimal force. Once dry, P-80 stops lubricating and parts remain in place, resulting in a tight fit. Since P-80 does not contain silicon or any other persistent ingredients, once dry the slipping action goes away.

    P-80 is used by many automotive OEM’s, suppliers and repair shops to ease the force needed to install rubber parts such as bushings, hoses, O-rings, belts and gaskets. Some common automotive applications are illustrated here:

    P-80 lubricants work so well for automotive assembly applications that the full line of P-80 lubricants was awarded with the 2012 North American Automotive Assembly Lubricants Product Leadership Award by Frost & Sullivan. Read the full report here.

    The next time you’re having trouble pushing a hose into place, inserting a window seal or installing suspension bushings try using P-80 lubricants and see how much easier the job becomes. Temporary lubricants are ideal for automotive use because they reduce the friction needed for assembly and repair without damaging the parts.

    Want more information about temporary rubber assembly lubricants, including how to use them and factors to consider when choosing a lubricant?  Download IPC’s free P-80® webinar.  Want to try P-80 for your automotive assembly needs?  Request a free sample. Or contact our technical team to help you find the best solution for your assembly needs.

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SOILS Micro-90® Micro® Green Clean Micro® A07 Surface-Cleanse/930® LF2100® Zymit® Low-Foam Zymit® Pro
Adhesives
Biofilm
Biological soils: Blood, Feces, Mucous, Sebum, Sweat, Urine
Dyes, Inks
Eggs, Butter, Fruit Stains
Emulsifiers
Fat
Fingerprints
Flavor, Fragrances
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Insoluble Salts
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Oxides
Paraffins
Petrolatum
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Tar
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