ADDED SEAL

Abstract

A additively manufactured seal comprising a main body having an outer wall, an inner wall opposite the outer wall, and a hollow chamber defined by the inner wall. The additively manufactured seal further comprises an uncured powder core disposed within the hollow chamber.

Description

[0001] The present invention relates generally to a seal and, more particularly, to an additively manufactured seal.

[0002] Press-in-place (PIP) seals are commonly used in engines (e.g., camshaft covers, oil pans, front covers, water pumps, etc.), transmissions (side covers, transmission pans, electrical module covers, etc.), electrical systems, and power systems. In many cases, PIP seals are designed to fit into complex groove patterns on mating surfaces of an interface. Additionally, these seals are engineered to withstand a wide range of environments, fluids, pressures, and temperatures.

[0003] For further background information, please refer to the documents DE 10 2017 206 065 A1, DE 11 2019 000 294 T5 and JP 7 321 061 B2.

[0004] The tooling required to manufacture these conventional PIP seals is time-consuming. Therefore, there is a need to manufacture seals without resorting to traditional injection molding techniques. SUMMARY

[0005] According to the invention, a generatively manufactured seal is presented which is characterized by the features of claim 1.

[0006] The seal comprises a main body having an outer wall, an inner wall opposite the outer wall, and a hollow chamber defined by the inner wall. The additively manufactured seal further comprises an uncured powder core disposed in the hollow chamber.

[0007] Implementations of the invention may include one or more of the following optional features. For example, the main body may include a first feature extending from the outer wall in a first portion. The first feature may be a stabilizing feature and may be at least partially embedded in the main body. The main body may include a second feature extending from the outer wall in a second portion. The second feature may be a retaining feature and may be at least partially embedded in the main body.

[0008] According to at least one aspect, the additively manufactured seal further comprises a total seal volume. The uncured powder core can occupy between 75% and 90% of the total seal volume.

[0009] In another aspect, the main body and the uncured powder core may both be made of a thermoplastic urethane.

[0010] In at least one example, the main body includes a height, a gap, and a thickness between the inner wall and the outer wall. The height may be greater than 7.8 millimeters (mm) and less than 8.5 mm, the gap may be greater than 1.0 mm and less than 1.5 mm, and the thickness may be greater than 0.5 mm and less than 1.0 mm.

[0011] Further described is a vehicle that includes a vehicle component that includes an additively manufactured seal. The additively manufactured seal includes a main body made from a thermoplastic urethane material that includes an outer wall defining a height of the main body, an inner wall opposite the outer wall that defines a gap of the main body, a thickness between the outer wall and the inner wall, and a hollow chamber defined by the inner wall, the hollow chamber having a seal chamber volume. The main body further includes one or more intermittent retention features, including a first feature extending from the outer wall and a second feature spaced from the first feature and extending from the outer wall.The additively manufactured seal further comprises an uncured powder core made of the same material as the main body and arranged in the hollow chamber, wherein the uncured powder core has a powder volume substantially similar to the volume of the seal chamber.

[0012] Implementations of the invention may include one or more of the following optional features. For example, the height of the additively manufactured seal may be greater than 7.8 millimeters (mm) and less than 8.5 mm, the gap of the additively manufactured seal may be greater than 1.0 mm and less than 1.5 mm, and the thickness of the additively manufactured seal may be greater than 0.5 mm and less than 1.0 mm.

[0013] In at least one aspect, the first feature of the additively manufactured seal may be a stabilizing feature and may be at least partially embedded in the main body. The second feature of the additively manufactured seal may be a retention feature at least partially embedded in the main body.

[0014] In another aspect, the additively manufactured seal may further comprise a total seal volume. The uncured powder core of the additively manufactured seal may occupy between 75% and 90% of the total seal volume.

[0015] A method for manufacturing a seal is also described, comprising additively manufacturing a main body comprising an outer wall, an inner wall opposite the outer wall, a hollow chamber defined by the inner wall, and one or more features extending from the outer wall. The method for manufacturing a seal further comprises treating the outer surface of the main body.

[0016] Implementations of the invention may include one or more of the following optional features. For example, the hollow chamber comprises an uncured powder core. The uncured powder may be made of the same material as the main body.

[0017] In at least one aspect, treating the outer surface of the main body further comprises vapor polishing the outer wall and the one or more features. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] The drawings described herein are for illustrative purposes only, illustrating selected configurations. Fig. 1 is a perspective view of a seal according to the principles of the present invention; Fig. 2 is a fragmentary perspective view of a seal disposed in a groove according to the principles of the present invention; Fig. 3A is a cross-sectional view of the seal of Fig. 2 in line 3A-3A; Fig. 3B is a cross-sectional view of the seal of Fig. 2 in line 3B-3B; Fig. 3C is a cross-sectional view of the seal of Fig. 2 in line 3C-3C; Fig. 4 is a fragmentary perspective view of another configuration of a seal disposed in a groove according to the principles of the present invention; Fig. 5A is a cross-sectional view of the seal of Fig. 4 in line 5A-5A; Fig. 5B is a cross-sectional view of the seal of Fig. 4 in line 5B-5B; Fig. Figure 5C is a cross-sectional view of the seal of Fig. 4 in line 5C-5C; Fig. 6 is a fragmentary perspective view of another configuration of a seal disposed in a groove according to the principles of the present invention; Fig. 7 is a cross-sectional view of the seal of Fig. 6 in line 7-7; Fig. Figure 8A is a cross-sectional view of the seal of Fig. 1 under compression of a mass according to the principles of the present invention; Fig. 8B is a diagram of a Kevin Voigt material model system according to the principles of the present invention; and Fig. Figure 9 is a flow diagram illustrating a method for manufacturing a gasket according to the principles of the present application. Corresponding reference numerals indicate corresponding parts throughout the drawings. DETAILED DESCRIPTION

[0019] With reference to Fig. 1, an additively manufactured seal 10 is provided. The seal 10 may also be referred to as a press-in-place (PIP) seal. Traditionally, PIP seals are manufactured using injection molding techniques, have a solid core (i.e., no hollow section), and can be used in a variety of environments, fluids, pressures, and temperatures. Manufacturing seals using other techniques, such as additive manufacturing, presents several challenges not encountered with conventional injection-molded or solid-core seals.

[0020] With reference to Fig. Figure 2 illustrates a fragmentary perspective view of another configuration of an additively manufactured seal 100 disposed within a portion of a groove 50. In this example, the groove 50 is four millimeters (mm) wide and six millimeters deep. It should be noted that the principles of the present invention also apply to grooves of different shapes, sizes, and / or dimensions.

[0021] With reference to Fig. 2 and 3A-3C, the seal 100 may include a main body 102 having an outer wall 104, an inner wall 106 opposite the outer wall 104, and a hollow chamber 108 defined by the inner wall 106. The hollow chamber 108 includes a seal chamber volume 110. The seal chamber volume 110 may be represented as the product of the cross-sectional area of ​​the hollow chamber 108 and the length of the circumference of the seal 100. The main body 102 may be further defined by a height 112, a width 113, a gap 114, and a thickness 116 between the inner wall 106 and the outer wall 104. In the present example, the height 112 may be greater than 7.8 mm and less than 8.5 mm, the gap 114 may be greater than 1.0 mm and less than 1.5 mm, and the thickness 116 may be greater than 0.5 mm and less than 1.0 mm. The main body 102 may have a substantially oval shape, as shown in Fig. 3A. Additionally, the main body 102 may be made of thermoplastic urethane (TPU), thermoplastic elastomers (TPE), or another material used, for example, for additive manufacturing (e.g., polymer powder bed fusion) of vehicle components.

[0022] The main body 102 may include one or more intermittent retention features 118. The one or more intermittent retention features 118 may be at least partially embedded within the main body 102 and / or extend from the outer wall 104. The one or more intermittent retention features 118 may include a first feature 120 and a second feature 122. The first feature 120 may be a stabilizing feature that stabilizes the seal 100 in the groove 50. The first feature 120 may be further defined by a first width 124 and a first height 126. The first width 124 is less than the width of the groove 50 and the first height 126 is greater than half the height 112 of the seal 100. The second feature 122 is spaced from the first feature 120 and may be referred to as a retention feature that retains the seal 100 within the groove 50.The second feature 122 may be further defined by a second width 128 and a second height 130. The second width 128 is greater than the width of the groove 50, and the second height 130 is greater than half the height 112 of the seal 100.

[0023] With reference to Fig. 3A, Fig. 3B and Fig. 3C, the seal 100 may further include an uncured powder core 132 disposed within the hollow chamber 108. In the present configuration, the uncured powder core 132 is made of the same material as the main body 102. Thus, if the main body 102 is manufactured using thermoplastic urethane, the uncured powder core 132 is also made of thermoplastic urethane in its raw and unprocessed state. The uncured powder core 132 may occupy between 75% and 90% of the total seal volume of the seal 100. The total seal volume may include the volume of the main body 102 and the chamber volume 110 occupied by the uncured powder core 132.

[0024] To begin manufacturing the additively manufactured seal 100, a thin layer of material (e.g., thermoplastic urethane powder) is melted using a laser or ultraviolet (UV) light to form a single anisotropic layer. A second thin layer of material (e.g., thermoplastic urethane powder) is provided on top of the first layer and treated with the laser or UV light to form the first and second layers together as a single anisotropic structure. This process can be repeated until the main body 102 is formed as a single anisotropic structure. During manufacturing of the seal 100, the selected material is not treated by the laser or UV light and thus remains uncured (i.e., it does not undergo any material-altering process).In other words, the uncured powder core 132 is gradually enclosed within the main body 102 while the main body 102 is additively manufactured around the uncured powder core 132. As discussed in more detail below, the uncured powder core 132 can serve as a pressure pot, providing stability when the seal 100 is subjected to compressive loads, achieving a compression ratio greater than 20% for a robust seal. The additive manufacturing of the seal 100 ensures that the main body 102 is airtight and can withstand a wide temperature range without failure.

[0025] Fig. 4, Fig. 5A, Fig. 5B and Fig. 5C illustrate another illustrative configuration of an additively manufactured seal 200. This configuration is similar in many respects to the configuration of Fig. 2, Fig. 3A, Fig. 3B and Fig. 3C. Accordingly, the descriptions of the configurations are hereby merged, and the description of items common to the configurations generally need not be repeated.

[0026] With reference to Fig. 4, the additively manufactured seal 200 is provided and arranged in a portion of the groove 50. The seal 200 may include a main body 202 having an outer wall 204, an inner wall 206 opposite the outer wall 204, and a hollow chamber 208 defined by the inner wall 206, as shown in Fig. 5A. The hollow chamber 208 includes a sealing chamber volume 210. In the present configuration, the main body 202 may have a substantially diamond shape. The main body 202 may be further defined by a height 212, a width 213, a gap 214, and a thickness 216 between the inner wall 206 and the outer wall 204.

[0027] With reference to Fig. 5B and Fig. 5C, the main body 202 may include one or more intermittent retention features 218. The one or more intermittent retention features 218 may be at least partially embedded within the main body 202 and / or extend from the outer wall 204. The one or more intermittent retention features 218 may include a first feature 220 and a second feature 222. The first feature 220 may be a stabilizing feature that stabilizes the seal 200 in the groove 50. The first feature 220 may be further defined by a first width 224 and a first height 226. The first width 224 is less than the width of the groove 50 and the first height 226 is greater than half the height 212 of the seal 100. The second feature 222 is spaced from the first feature 220 and may be referred to as a retention feature that retains the seal 100 within the groove 50.The second feature 222 may be further defined by a second width 228 and a second height 230. The second width 228 is greater than the width of the groove 50, and the second height is greater than half the height 212 of the seal 100.

[0028] With reference to Fig. 5A, Fig. 5B and Fig. 5C, the seal 200 may further include an uncured powder core 232 disposed within the hollow chamber 208. In the present configuration, the uncured powder core 232 is made of the same material as the main body 202.

[0029] Fig. 6 and Fig. 7 illustrate another illustrative configuration of an additively manufactured seal 300. This configuration is similar in many respects to the configurations in Fig. 2 and 3A-3C and Fig. 4 and 5A-5C. Accordingly, the descriptions of the configurations are hereby merged, and the description of items common to the configurations generally need not be repeated.

[0030] With reference to Fig. 6, the additively manufactured seal 300 is provided and arranged in a portion of a groove 50. The seal 300 may include a main body 302 having an outer wall 304, an inner wall 306 opposite the outer wall 304, and a hollow chamber 308 defined by the inner wall 306, as shown in Fig. 7. The hollow chamber 308 includes a sealing chamber volume 310. In the present configuration, the main body 302 may have a generally marquise shape, as shown in Fig. 7. The main body 302 may be further defined by a height 312, a width 313, a gap 314, and a thickness 316 between the inner wall 306 and the outer wall 306.

[0031] With reference to Fig. 7, the main body 302 may include one or more intermittent retention features 318. The one or more intermittent retention features 318 may be at least partially embedded within the main body 302 and / or extend from the outer wall 304. The one or more intermittent retention features 318 may include a ribbed feature 336. The ribbed feature 336 may be referred to as a retention feature that retains the seal 300 within the groove 50. Compared to the first features 120, 220 and the second features 122, 222 of the seals 100, 200, there is less contact between each ribbed feature 336 and the groove 50. The ribbed feature 336 may be further defined by a rib height 338 that is less than half the height 312 of the seal 300.

[0032] With reference to Fig. 7, the seal 300 may further include an uncured powder core 332 disposed within the hollow chamber 308. In the present configuration, the uncured powder core 332 is made of the same material as the main body 302.

[0033] With reference to Fig. 8A and Fig. 8B, the seals 100, 200, 300 of the present invention can be compared to the Kevin-Voigt material model 400 when subjected to compressive loads by a mass 402 (i.e., represented as m in Fig. 8B). The mass 402 may be a grooveless fitting flange that is pressed onto the seal 100 during the closing of the connection. With reference to Fig. 8, the main body 102 can act as a spring 404 and have a spring constant 406 (ie spring constant k in Fig. 8B). In addition, the uncured powder core 132 may act as a pressure pot 408 and have a damping coefficient 410 (i.e., damping coefficient c in Fig. 8B). The uncured powder 132 provides some degree of damping during joint closure and may be desirable for maintaining the stability of the cross-section (e.g., so that it is less susceptible to buckling during joint closure).

[0034] With reference to Fig.9, a method 500 is provided for manufacturing seals 100, 200, 300 according to the principles of the present invention. At 510, method 500 is initiated. In practice, method 500 is initiated when an additive manufacturing machine or chamber (e.g., 3D printer, powder bed fusion machine, etc.) is programmed to design, manufacture, and / or produce at least one of seals 100, 200, 300. The remaining steps of method 500 are discussed with reference to manufacturing seal 100, but equally apply to manufacturing seals 200 and 300.

[0035] At 520, the main body 102 is additively manufactured to include the outer wall 104, the inner wall 106 opposite the outer wall 104, the hollow chamber 108 defined by the inner wall 106, and the one or more intermittent retention features 118 at least partially embedded in the main body 102 and / or extending from the outer wall 104. During 502, as mentioned above, the uncured powder core 132 is enclosed by the main body 102 while the main body 102 is additively manufactured.

[0036] At 530, the outer wall 104 is treated with a surface treatment process, such as vapor polishing. After 520, the outer wall 104 may have some degree of irregularities and / or surface porosity that can be eliminated with vapor polishing or another surface treatment process. Treating the surface of the outer wall 104 may be desirable to improve the performance of the seal 100 and prevent leaks that might otherwise result from surface porosities.

[0037] At 540 the procedure ends 500.

Claims

[1] Additively manufactured seal (100, 200, 300), comprising: a main body (102, 202, 302) comprising: an outer wall (104, 204, 304), an inner wall (106, 206, 306) opposite the outer wall (104, 204, 304) and a hollow chamber (108, 208, 308) defined by the inner wall (106, 206, 306) and an uncured powder core (132, 232, 332) arranged in the hollow chamber (108, 208, 308). [2] The additively manufactured seal of claim 1, wherein the main body comprises a first feature (120, 220) extending from the outer wall (104, 204) in a first portion. [3] The additively manufactured seal of claim 2, wherein the first feature (120, 220) is a stabilizing feature and is at least partially embedded in the main body (102, 202). [4] The additively manufactured seal of claim 3, wherein the main body (102, 202) includes a second feature (122, 222) extending from the outer wall (104, 204) in a second portion. [5] The additively manufactured seal of claim 4, wherein the second feature (122, 222) is a retention feature (118, 218) and is at least partially embedded in the main body (102, 202). [6] The additively manufactured seal of claim 1, further comprising a total seal volume. [7] Additively manufactured seal according to claim 6, wherein the uncured powder core occupies between 75% and 90% of the total seal volume. [8] The additively manufactured seal of claim 1, wherein the main body (102, 202, 302) and the uncured powder core (132, 232, 332) are both made of a thermoplastic urethane. [9] The additively manufactured seal of claim 1, wherein the main body (102, 202, 302) includes a height (112, 212, 312), a gap (114, 214, 314) and a thickness (116, 216, 316) between the inner wall (106, 206, 306) and the outer wall (104, 204, 304). [10] The additively manufactured seal of claim 9, wherein the height (112, 212, 312) is greater than 7.8 millimeters (mm) and less than 8.5 mm, the gap (114, 214, 314) is greater than 1.0 mm and less than 1.5 mm, and the thickness (116, 216, 316) is greater than 0.5 mm and less than 1.0 mm.

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