Rotary seal and method of making same

1. A method for producing a seal, comprising:

(a) providing a mold ( 22 ) for producing an annular polymeric seal ( 60 ), the mold ( 22 ) comprising:

a mold core ( 24 ) comprising:

a lip forming surface ( 54 ) of annular form and facing in a generally radially outward direction;

an inner groove wall ( 50 ) of annular form facing in a generally radially outward direction;

a cavity groove end ( 48 ) having at least a portion thereof facing in a generally axial direction,

the inner groove wall ( 50 ) located in axially intermediate relation to the lip forming surface ( 54 ) and the cavity groove end ( 48 ), and the lip forming surface ( 54 ) radially recessed relative to the inner groove wall ( 50 );

a mold cap ( 28 ) having a cap wall ( 36 ) of annular form facing in a generally axial direction toward the cavity groove end ( 48 ), the lip forming surface ( 54 ) located in axially intermediate relation to the cap wall ( 36 ) and the inner groove wall ( 50 ) and located in axially intermediate relation to the cap wall ( 36 ) and the cavity groove end ( 48 );

a mold collar ( 26 ) having a collar cavity surface ( 42 ) of annular form facing generally radially inward toward and surrounding at least a portion of the lip forming surface ( 54 );

one of the mold collar ( 26 ) and the mold core ( 24 ) having a mold shoulder ( 44 ) of annular form facing in a generally axial direction toward the cap wall ( 36 ), at least a portion of the collar cavity surface ( 42 ) located in axially intermediate relation to the mold shoulder ( 44 ) and the cap wall ( 36 ) and at least a portion of the lip forming surface ( 54 ) located in axially intermediate relation to the mold shoulder ( 44 ) and the cap wall ( 36 );

one of the mold collar ( 26 ) and the mold core ( 24 ) having an outer groove wall ( 52 ) of annular form facing radially inward toward and surrounding at least a portion of the inner groove wall ( 50 ), at least a portion of the outer groove wall ( 52 ) located in axially intermediate relation to the cavity groove end ( 48 ) and the mold shoulder ( 44 ), and the outer groove wall ( 52 ) located in axially intermediate relation to the cavity groove end ( 48 ) and the cap wall ( 36 ); and

the cavity groove end ( 48 ), the inner groove wall ( 50 ), and the outer groove wall ( 52 ) defining a cavity groove ( 46 ) for forming an axial extension ( 74 ) of a polymeric seal ( 60 );

(b) providing a plastic liner ( 2 ) of annular form, the plastic liner ( 2 ) having first and second liner end surfaces ( 8 , 10 ) facing in generally opposite axial directions and having a liner inner surface ( 4 ) and a liner outer surface ( 6 ) facing in generally opposite radial directions and located in axially intermediate relation to the first and second liner end surfaces ( 8 , 10 );

(c) installing the plastic liner ( 2 ) on the mold core ( 24 ) with a portion of the liner inner surface ( 4 ) facing toward and surrounding at least a portion of the inner groove wall ( 50 ) and with a portion of the liner inner surface ( 4 ) facing toward and surrounding at least a portion of the lip forming surface ( 54 ) and with a portion of the liner outer surface ( 6 ) encircled by the mold shoulder ( 44 );

(d) after step (c) introducing an elastomer ( 58 ) between the liner outer surface ( 6 ) and the collar cavity surface ( 42 ) and applying pressure and temperature to vulcanize the elastomer ( 58 ) and remold the liner inner surface ( 4 ) to the shape of the lip forming surface ( 54 );

(e) using the mold ( 22 ) to produce an annular polymeric seal ( 60 ) having:

a lubricant end ( 62 ) and an environment end ( 64 ) facing in generally opposite, generally axial directions and separated by a distance, the lubricant end ( 62 ) facing generally away from the environment end ( 64 );

an inward surface ( 76 ) of annular form facing in a generally radially inward direction;

an axial extension ( 74 ) of annular form extending axially beyond the lubricant end ( 62 ) and formed at least in part from the inward surface ( 76 ) and having an outward surface ( 78 ) facing in a generally radially outward direction away from the inward surface ( 76 ) and encircling at least a portion of the inward surface ( 76 ), the outward surface ( 78 ) located in radially intermediate relation to the inward surface ( 76 ) and the lubricant end ( 62 );

a dynamic lip ( 80 ) of annular form projecting radially inward relative to the inward surface ( 76 ) and having a dynamic sealing surface ( 82 ) of annular form facing in a generally radially inward direction;

a liner ( 2 ) of annular form composed of plastic defining the dynamic sealing surface ( 82 ), the axial extension ( 74 ) located in radially intermediate relation to the dynamic sealing surface ( 82 ) and the lubricant end ( 62 ); and

(f) removing at least a portion of the axial extension ( 74 ) by a machining operation, producing a machined seal surface ( 110 ) facing in a generally axial direction away from the environment end ( 64 ) and located in radially intermediate location to the lubricant end ( 62 ) and the dynamic sealing surface ( 82 ).

2. A method for producing a seal, comprising:

(a) providing an annular seal ( 60 ) having:

a lubricant end ( 62 ) and an environment end ( 64 ) facing in generally opposite, generally axial directions and separated by a distance, the lubricant end ( 62 ) facing generally away from the environment end ( 64 );

a static sealing surface ( 70 ) facing in a radially outward direction and adjoining the environment end ( 64 );

an inward surface ( 76 ) of annular form facing in a generally radially inward direction;

an axial extension ( 74 ) of annular form extending axially beyond the lubricant end ( 62 ) and away from the environment end ( 64 ) and formed at least in part from the inward surface ( 76 ) and having an outward surface ( 78 ) facing in a generally radially outward direction away from the inward surface ( 76 ) and encircling at least a portion of the inward surface ( 76 ), the outward surface ( 78 ) located in radially intermediate relation to the inward surface ( 76 ) and the lubricant end ( 62 );

a dynamic lip ( 80 ) of annular form projecting radially inward relative to the inward surface ( 76 ) and having a dynamic sealing surface ( 82 ) of annular form facing in a generally radially inward direction, the dynamic sealing surface ( 82 ) adjoining the environment end ( 64 ),

wherein the environment end ( 64 ) is a generally planar surface extending between the dynamic sealing surface ( 82 ) and the static sealing surface ( 70 ); and

a liner ( 2 ) of annular form composed of plastic defining the dynamic sealing surface ( 82 ), the axial extension ( 74 ) located in radially intermediate relation to the dynamic sealing surface ( 82 ) and the lubricant end ( 62 ); and

(b) removing at least a portion of the axial extension ( 74 ) by a machining operation, producing a machined seal surface ( 110 ) facing in a generally axial direction away from the environment end ( 64 ) and located in radially intermediate location to the lubricant end ( 62 ) and the dynamic sealing surface ( 82 ).

3. The method of claim 2 , wherein a portion of the machined seal surface ( 110 ) is formed by the liner ( 2 ).

4. The method of claim 2 , wherein the machining operation removes a portion of the liner ( 2 ).

5. The method of claim 2 , wherein the machining operation truncates a portion of the dynamic lip ( 80 ).

6. The method of claim 2 , wherein the machined seal surface ( 110 ) is substantially even with the lubricant end ( 62 ).

7. The method of claim 2 , wherein the machined seal surface ( 110 ) is separated from the environment end ( 64 ) by a distance, and the distance separating the machined seal surface ( 110 ) from the environment end ( 64 ) is substantially the same as the distance separating the lubricant end ( 62 ) from the environment end ( 64 ).

8. The method of claim 2 , wherein prior to the machining operation the outward surface ( 78 ) is located radially outward of and encircles at least a portion of the liner ( 2 ).

9. The method of claim 2 , wherein prior to the machining operation the lubricant end ( 62 ) is located radially outward of and encircles at least a portion of the liner ( 2 ).

10. The method of claim 2 , wherein the liner ( 2 ) forms at least part of the environment end ( 64 ).

11. The method of claim 2 , wherein prior to the machining operation a relief groove surface ( 72 ) is located in radially intermediate relation to the axial extension ( 74 ) and the lubricant end ( 62 ) and at least part of the relief groove surface ( 72 ) is located in axially intermediate relation to the lubricant end ( 62 ) and the environment end ( 64 ),

wherein the relief groove surface ( 72 ) intersects and adjoins the outward surface ( 78 ) of the axial extension ( 74 ).

12. The method of claim 11 , wherein the relief groove surface ( 72 ) is located radially outward of and encircles a portion of the inward surface ( 76 ).

13. The method of claim 2 , wherein the annular seal further comprises a relief groove ( 73 ) located in radially intermediate relation to the lubricant end ( 62 ) and the axial extension ( 74 ) and radially outward of and encircling a portion of the liner ( 2 ), and at least part of the relief groove ( 73 ) located in axially intermediate relation to the lubricant end ( 62 ) and the environment end ( 64 ).

14. The method of claim 2 , wherein prior to the machining operation the lubricant end ( 62 ) is located radially outward of and encircles a portion of the inward surface ( 76 ) and a portion of the liner ( 2 ).

15. The method of claim 2 , wherein a relief groove surface ( 72 ) is located in radially intermediate relation to the machined seal surface ( 110 ) and the lubricant end ( 62 ) and at least part of the relief groove surface ( 72 ) is located in axially intermediate relation to the lubricant end ( 62 ) and the environment end ( 64 ).

16. A method for producing a seal, comprising:

(a) providing a mold ( 22 ) for producing an annular polymeric seal ( 60 ), the mold ( 22 ) comprising a mold core ( 24 ), a mold cap ( 28 ) and a mold collar ( 26 ), wherein the mold core ( 24 ), mold cap ( 28 ) and mold collar ( 26 ) have surfaces defining a mold cavity ( 32 ) comprising:

a lip forming surface ( 54 ) of annular form adjoining an inner groove wall ( 50 ) of annular form, the lip forming surface ( 54 ) and inner groove wall ( 50 ) facing in a generally radially outward direction and the lip forming surface ( 54 ) radially recessed relative to the inner groove wall ( 50 );

a cavity groove end ( 48 ) joining an end of the inner groove wall ( 50 ), at least a portion of the cavity groove end ( 48 ) facing in a generally axial direction;

a cap wall ( 36 ) of annular form facing in a generally axial direction toward the cavity groove end ( 48 );

a mold shoulder ( 44 ) of annular form facing in a generally axial direction toward the cap wall ( 36 );

a collar cavity surface ( 42 ) of annular form facing generally radially inward toward and surrounding at least a portion of the lip forming surface ( 54 );

an outer groove wall ( 52 ) of annular form facing radially inward toward and surrounding at least a portion of the inner groove wall ( 50 ); and

the cavity groove end ( 48 ), the inner groove wall ( 50 ), and the outer groove wall ( 52 ) defining a cavity groove ( 46 ) for forming an axial extension ( 74 ) of a polymeric seal ( 60 );

(b) providing a plastic liner ( 2 ) of annular form having first and second liner end surfaces ( 8 , 10 ) facing in generally opposite axial directions and having a liner inner surface ( 4 ) and a liner outer surface ( 6 ) facing in generally opposite radial directions and located in axially intermediate relation to the first and second liner end surfaces ( 8 , 10 ),

(c) installing the plastic liner ( 2 ) on the mold core ( 24 ) with the first liner end surface ( 8 ) adjoining the cavity groove end ( 48 ), a portion of the liner inner surface ( 4 ) facing generally radially inward toward and encircling at least a portion of the inner groove wall ( 50 ), and a portion of the liner inner surface ( 4 ) facing generally radially inward toward and encircling at least a portion of the lip forming surface ( 54 );

(d) after installing the plastic liner ( 2 ) on the mold core ( 24 ) with the first liner end surface ( 8 ) adjoining the cavity groove end ( 48 ), introducing an elastomer ( 58 ) between the liner outer surface ( 6 ) and the collar cavity surface ( 42 ) and applying pressure and temperature to vulcanize the elastomer ( 58 ) and remold the liner inner surface ( 4 ) to the shape of the lip forming surface ( 54 );

(e) producing an annular polymeric seal ( 60 ) having:

a lubricant end ( 62 ) shaped by the mold shoulder ( 44 );

an environment end ( 64 ) shaped by the cap wall ( 36 );

an axial extension ( 74 ) of annular form extending axially beyond the lubricant end ( 62 ) and shaped at least in part by the inner and outer groove walls ( 50 , 52 ) and the cavity groove end ( 48 );

an inward surface ( 76 ) of annular form facing in a generally radially inward direction and shaped by the inner groove wall ( 50 ); and

a dynamic lip ( 80 ) of annular form projecting radially inward relative to the inward surface ( 76 ) and having a dynamic sealing surface ( 82 ) of annular form facing in a generally radially inward direction and formed by the liner inner surface ( 4 ); and

(f) removing at least a portion of the axial extension ( 74 ) by a machining operation, producing a machined seal surface ( 110 ) facing in a generally axial direction away from the environment end ( 64 ) and located in radially intermediate location to the lubricant end ( 62 ) and the dynamic sealing surface ( 82 ).

17. The method of claim 16 , wherein the machining operation truncates a portion of the dynamic lip ( 80 ).

18. The method of claim 16 , wherein a portion of the machined seal surface ( 110 ) is formed by the liner ( 2 ).

19. The method of claim 16 , wherein the machining operation removes a portion of the liner ( 2 ).

20. The method of claim 16 , wherein the machined seal surface ( 110 ) is substantially even with the lubricant end ( 62 ).

21. The method of claim 16 , wherein the machined seal surface ( 110 ) is separated from the environment end ( 64 ) by a distance, and the distance separating the machined seal surface ( 110 ) from the environment end ( 64 ) is substantially the same as the distance separating the lubricant end ( 62 ) from the environment end ( 64 ).

22. The method of claim 16 , wherein prior to the machining operation the lubricant end ( 62 ) is located radially outward of and encircles at least a portion of the liner ( 2 ).

23. The method of claim 16 , wherein the liner ( 2 ) forms at least part of the environment end ( 64 ).

24. The method of claim 16 , wherein the annular seal further comprises a relief groove ( 73 ) located in radially intermediate relation to the lubricant end ( 62 ) and the axial extension ( 74 ) and radially outward of and encircling a portion of the liner ( 2 ), and at least part of the relief groove ( 73 ) located in axially intermediate relation to the lubricant end ( 62 ) and the environment end ( 64 ).

25. The method of claim 16 , wherein prior to the machining operation the lubricant end ( 62 ) is located radially outward of and encircles a portion of the inward surface ( 76 ) and a portion of the liner ( 2 ).

26. The method of claim 16 , wherein a relief groove surface ( 72 ) is located in radially intermediate relation to the machined seal surface ( 110 ) and the lubricant end ( 62 ) and at least part of the relief groove surface ( 72 ) is located in axially intermediate relation to the lubricant end ( 62 ) and the environment end ( 64 ).