Cold static gasket for complex geometrical sealing applications

A gasket assembly and method for forming the gasket assembly for sealing two mating surfaces over a complex geometrical contact region. The gasket assembly is formed by a hollow silicone rubber tube having a naturally straight configuration but easily bent into complex configurations without kinking. The tube is filled with a curable liquid rubber compound and then the ends of the tube are joined in end-to-end fashion to form a continuous loop. The joined ends of the tube can be reinforced with a connector and then locally cured on a preliminary operation so that the liquid rubber compound does not escape. The tube is then laid up in a mold having a complex geometrical feature which replicates the complex geometrical contact region of the two mating surfaces to be subsequently sealed. With the tube held stationary in the mold form, the entrapped liquid rubber compound is cured using a heat source or other suitable curing accelerant. Once fully cured, the core of rubber compound (′) takes a set in the complex geometrical form, and resists straightening of the tube so as to hold the gasket assembly in the complex geometrical shape required to later seal the mating surfaces. The tube and core of cured rubber compound (′) may be selected of materials which possess different durometers.