1. Jump to first page Armada Rubber Mfg. Co. Expert System

2. Jump to first page Table of Contents n Head type suggestions for the application n Armada Rubber head (types) n Interior Bumpers - Ashtrays - Glove box - Console - Grab handles n Exterior Bumpers - Fuel filler door - Hood and Deck Lid - Door handles - License plates n Recessed Bumpers n Suggestions for design & correcting BSR issues n Installation notes n Hole Plugs n Grommets n Caps n Line Plugs n Materials

3. Jump to first page Head type suggestions for the application Due to the number of variables involved i.e. durometers, materials, and geometry there is no formula to predict load deflections or closure forces involved. It is important to understand the does not compress but had to deflect from its original shape. The following might be helpful in determining the desirable geometry of the head (type) for the application. Look at the bumper listing in the Armada Rubber mold listing book to get a better visual of the head (types) explained on the following page(s).

4. Jump to first page Armada Rubber head (types) Type 1) Similar to type 3 with minimal deflection. These are generally shorter in head height. Type 2 & 5) Have smaller contact patches and allow greater deflection than either types 1,3 or 4. Type 3) Has the least amount of deflection, generally specified to hold large trim or panels stable under greater load forces. This (type) has a large contact patch, which is used in many instances as overslam bumpers. This (type) quickly absorbs energy and protects components from over-travel. NOTE: The strength of the sheet metal is important so that the load put on the bumper does not bend the metal.

5. Jump to first page Armada Rubber head (types) cont. Type 4) Gives greater stability for areas needing taller bumpers with some degree of deflection. Type 6) Conical Hollow Head design deflects easily and has a more linear compression curve, allowing for a wider range of design gap. This is generally softer and quieter, which works well in interior applications. This head design is good for interior applications such as consoles and glove boxes.

6. Jump to first page Interior Bumpers - 1) Ashtray Bumpers 1) Determine trim and finish line which will determine the gap between the closure and the fixed dimension 2) Check allowable geography for maximum diameter of bumper head along with location of hole and allowable hole size to fasten the bumper either to the closure or the fixed dimension. Hole sizes should be line-to-line with the neck of the bumper. 3) The bumper’s groove thickness should be line-to-line or slightly smaller than the material thickness. 4) Pull-thru bumpers are preferred if there is enough room for installation. If there isn’t enough room for a pull-thru bumper then try a push-in bumper. Note: push-in bumpers require an installation tool. Pull-thru or push-thru are subject to assembly preferences.

7. Jump to first page Interior Bumpers - 2) Glove box 1) Determine the gap between the closure and fixed dimension.In general add 15% to the gap distance which will determine the head height of the bumper. This will create a slight interference fit, compressing the bumper. 2) Check allowable geography for maximum diameter of bumper head along with location of hole and allowable hole size. Hole size should be line-to-line with the neck of the bumper or slightly larger. 3) The bumper’s groove thickness should be from line-to- line with material thickness or smaller (generally up to 1.0 mm for softer rubber). 4) Pull-thru bumpers are preferred if assembly allows room for the tail to be pulled through from the backside. If there is not enough room for a pull-thru bumper than think about a push-in bumper. Push-in bumpers do require a tool for installation. 5) For glove box applications the Hollowhead bumper works best and are tolerant of a wide range of deflection/ gap filling without significantly increasing closure efforts.

8. Jump to first page Interior Bumpers - 3) Console Bumpers 1) Determine the gap between the closure and fixed dimension. In general add 15% to the gap distance which will determine the head height of the bumper. 2) Check allowable geography for maximum diameter of bumper head along with location of hole and allowable hole size to fasten bumper either to the closure or the fixed dimension. 3) The bumpers groove thickness should be from line-to- line with material thickness or smaller (generally 1.0 mm for softer rubber material). 4) If the assembly allows room to pull the tail of the bumper into the mounting hole from the backside of the assembly a pull-thru bumper would be easiest. If this is not applicable then a push-thru bumper should be looked at. Note: push-thru bumpers do require a tool for assembly. 5) For console applications hollow head bumpers work well. This type of bumper has a wide range of deflection/ gap filling without significantly increasing closure efforts. If the console needs to take a large load a solid head may be better.

9. Jump to first page Interior Bumpers - 4) Grab Handles 1) Check allowable geography for maximum diameter of bumper head along with location of hole and allowable hole size to fasten the bumper. The hole size should be line-to-line with the neck of the bumper or slightly larger. 2) The bumpers groove thickness should be from line-to- line with material thickness or smaller (generally up to 1.0 mm for softer rubber material). 3) Typically grab handle bumpers are push-in types. If assembly allows room to pull the tail of the bumper into the mounting hole from the backside of the assembly a pull-thru type bumper is easier.

10. Jump to first page Exterior Bumpers - 1) Fuel Filler Door 1) Determine inside of door and finish line which will determine the gap between the closure and fuel filler pocket. 2) Check allowable geography for maximum diameter of bumper head along with location of hole and allowable hole size to fasten bumper. 3) The bumpers groove thickness should be from line-to- line with material thickness 4) Typically these bumpers are of the push-in type, unless the bumpers can be assembled to the pocket as part of that assembly.

11. Jump to first page Exterior Bumpers - 2) Hoods and Deck Lids 1) Determine trim and finish line which will determine the gap between the closure and the fixed dimension. Note: Build Tolerances - the fit should encompass “touch” condition in the worst case. 2) Check allowable geography for maximum diameter of bumper head along with location of hole and allowable hole size to fasten bumper. Hole size should be line-to- line with the neck of the bumper or slightly larger. 3) The bumpers groove thickness should be close to line- to-line with material thickness. 4) Typically these bumpers are push-in style bumpers. Twist-in style bumpers can also be used if off - axis impact may cause the bumper to come out. The sheet metal must be shaped for the installation for the twist- in. Recess bumpers can be used as an attachment point, saving assembly steps. Contact ARMC/ Rep for recommendation.

12. Jump to first page Exterior Bumpers- 2) Hoods and Deck lids (cont.) 5) It is important to know how strong the sheet metal is so that the bumper won’t cause metal distortions when contact occurs. 6) Typically broad and solid bumpers are chosen for these applications.

13. Jump to first page Exterior Bumpers - 3) Door Handles 1) Check allowable geography for maximum diameter of bumper head along with location of hole and allowable hole size to fasten bumper. Hole size should be line-to- line with the neck of the bumper or slightly larger. 2) The bumper’s groove thickness should be from line-to- line with the material thickness. 3) Typically these bumpers have solid heads because they don’t have to take up distortions. 4) Pull-thru style bumpers are easier for installation. If the assembly allows room to pull the tail into the mounting hole from the backside of the assembly Pull-thru style bumper’s are preferred. If there isn’t enough room for a pull-thru bumper than a push-in bumper can be applied. 5) Due to more stringent crash test requirements, spring forces have been increased. See Armada/Rep for details.

14. Jump to first page Exterior Bumpers - 4) License plates 1) Determine the gap between the plate and fixed dimension. 2) Check allowable geography for maximum diameter of bumper head along with location of hole and allowable hole size to fasten to the closure or fixed dimension. Hole size should be line-to-line with the neck of the bumper or slightly larger. 3) The bumper’s groove thickness should be line-to-line with material thickness. 4) pull-thru style bumper’s are easiest for installation if the assembly allows room to pull the tail of the bumper into the mounting hole from the backside of the assembly. If not, push-in style bumpers are often used for license plate applications.

15. Jump to first page Recessed Bumpers 1) These bumpers are specifically designed to have a fastener installed into them, for example ( screw, etc. ). 2) If the bumper is to be shipped with the fastener in it, there must be restriction between the rubber and the fastener so that the fastener will stay in the bumper. 3) To resist torque damage under a screw head, a free spinning washer should be on the screw or installed in the bumper recess.

16. Jump to first page Suggestions for design & correcting BSR issues Checking for Trim Line: 1) Prototype model or existing assemblies - get math data showing nominal positions. You should understand tolerances. 2) Testing head heights and style for trim line and closure force for existing assemblies. After determination of style and type along with approximate head height select a group of Armada bumpers from the bumper listing. Contact representative or Armada directly for available parts. Do not rule out bumpers that are not optimal for existing hole size and substrate thickness. Objective is to determine head height and type. Can modifications be made to mounting surface to accommodate bumpers preference? If not, hand trim bumper retainer to test head height and type or remove head from bumper and mount head with double sided tape to surface.

17. Jump to first page Installation Notes 1) Insertion tools for push-in bumpers should have a diameter 25- 50% smaller than the insertion hole and should be able to stretch the neck of the part about 100%. The tip should be ground to a full radius to avoid puncturing the carrot. If a die roll is built into the substrate it will make the bumper much easier to install and still difficult to remove. 2) When designing a bumper the insertion hole should extend at least half way into the retainer. This will allow for the insertion tool to stretch the retainer far enough for easier installation. 3) If installation is difficult try using soapy water, so that the bumper will slide in easier.

18. Jump to first page Hole Plugs 1) There are two styles of hole plugs, so you need to determine which style works best for the application. On-plane sealing - this style has a mushroom shaped head that seals the hole. This plug works well for off- plane distortions or hole distortions. Radial sealing in the through hole - This plug has a diameter interference fit of 1 to 2 mm depending on the hole you are plugging.

19. Jump to first page Grommets 1) Grommets act as isolators or protect a part that travels through them. 2) The dimensions of a grommet must be close to that of the substrate it will be installed into. 3) Some grommets do accommodate metal distortions. 4) Typically 1.5 mm is the minimum thickness on the wall of a grommet. 5) Armada makes grommets in one piece and can split the grommet for certain applications. 6) Grommets for mounting applications such as ABS units mounted to the bracket and vehicle are critical for noise and vibration abatement.

20. Jump to first page Caps 1) Caps can be used to either keep fluid from flowing in or out of an area, can be used as a bumper, or as a stand off. 2) When designing a cap the thickness of the rubber should be no less than 1.5 mm. 3) Interference between the I.D. and O.D. should be 10 - 15%. 4) Installation efforts can be reduced by using soapy water.

21. Jump to first page Line Plugs 1) Line plugs require interference between parts for the plug to retain. This interference occurs between the inside diameter of the substrate and the outside diameter of the line plug.

22. Jump to first page Materials On the following page is a chart to help you select the correct type of rubber compound for your application. The chart will tell you how each compound responds under different conditions.

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