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Sponge Gaskets are usually used to fill the space between two or more highly irregular mating surfaces, generally to prevent leakage from or into the joined objects while under compression.

 

We manufacture over 500 different types of Sponge Rubber Gaskets. We can also manufacture sponge gaskets as per our customer sizes/drawings and customized technical requirements.

 

Sponge rubber, also called "expanded" or "cellular" rubber, is manufactured by including a gas-forming ingredient (blowing agent) in the rubber formulation. As the rubber vulcanises, it reaches a temperature at which the blowing agent decomposes and gas bubbles form, creating individual cell structures in the rubber. This is followed by a curing until vulcanization is complete. The vulcanization process preserves the cell structure formed by the gas in the interior of the component. This makes the final gasket softer, easier to compress and lighter in weight. Hence sponge gaskets require much lesser force to compress as compared to solid rubber gaskets.

 

Sponge Rubber gaskets can be specially compounded for:

 

  • Excellent Weather / UV resistance: For long product life
  • Ultra Low Compression Set: For IP65, IP66, IP67 levels of Protection.
  • High Heat Resistance: Usable up to 250 Degree Celsius
  • Food Grade Applications: FDA/BgVV/USP Class VI/WRAS Compliant

 

Choice of Elastomers:

Silicone Rubber Sponge
EPDM Rubber Sponge

 

Sizes offered

Moulded: Up to 1000 mm Max.
Extruded: Up to 75 mm CS. Larger sizes can be made against order.

 

Colours Offered

Standard: Black, White and Grey.

Customized Colours can also be offered against order.

 

Manufacturing Process

The Sponge Rubber Gaskets are manufactured by Extrusion / Moulding / Extrusion + Moulding, depending on the design and specifications of the requirements

 

Extruded Sponge Gaskets

We manufacture extruded sponge gaskets in our state-of-the-art Cold Feed Extruders and Continuous Vulcanization Extrusion Lines. The entire setup is fully automated and computer controlled, which enables us to deliver:

 

  • Very Accurate Dimensions: Computerized controls of the machine enable us to offer our customer excellent dimensional accuracy in the material.
  • Uniform Vulcanization / Curing of the Material: Since Vulcanization / Curing is being done as a continuous process rather than in a batch process, the material quality is better and more consistent. 
  • Excellent Surface Finish: We offer excellent surface finish in the Gaskets
  • Bend-less Extrusions: Due to the continuous curing process, the material is absolutely straight, without any bend, twist in the Gaskets. This increases ease of fitment.

 

Moulded Gaskets

Moulded sponge gaskets are manufactured by compression moulding in our Automatic Hydraulic Compression Moulding Presses.

Along with our in-house tool room, and highly experienced manufacturing team, our range of Moulding machines enable us to deliver:

  • Uniform Vulcanization / Curing of the Material: All parameters (like pressure, temperature and vulcanization time) are automatically controlled.
  • Excellent Dimensional Accuracy: We offer high dimensional accuracy in our Moulded Sponge Gaskets
  • Huge range of designs and sizes: We offer gaskets in a huge variety of designs/sizes.