3D-Printed Seal Caps for Conformal Fastener Sealing
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Solution Overview
Problem
Existing seal caps for fasteners lack optimal properties such as chemical resistance, corrosion resistance, hydrolytic stability, low temperature flexibility, and high temperature resistance, and often have limitations in conforming to complex fastener geometries, leading to voids and reduced reliability.
Innovation Solution
The method involves three-dimensional printing successive layers of coreactive compositions to form a seal cap shell and fill the interior with a second coreactive composition, allowing for optimized material properties and conformal sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional seal cap manufacturing methods are used, then production efficiency is maintained, but the seal cap cannot conform to complex fastener geometries, leading to voids and reduced reliability
Solution Approach 1:
The patent replaces traditional mechanical molding processes with three-dimensional printing technology. This substitution enables the seal cap to be deposited layer-by-layer directly onto the fastener, conforming to complex geometries that mechanical methods cannot achieve, thereby eliminating voids and improving sealing reliability
Solution Approach 2:
The patent utilizes the ability of three-dimensional printing to vary material parameters during the deposition process. By controlling the deposition parameters and material composition, the seal cap can be optimized to perfectly match the fastener's complex geometry, achieving superior conformality and eliminating the voids that plague traditional manufacturing methods
2Reliability
If seal caps are made with optimized material properties for specific applications, then performance in chemical resistance, corrosion resistance, and temperature resistance is improved, but the complexity of manufacturing increases
Solution Approach 1:
The patent applies local quality by enabling different material compositions to be deposited in different regions of the seal cap through three-dimensional printing. This allows optimization of specific areas for chemical resistance, corrosion resistance, or temperature resistance based on the local environmental conditions, while the additive manufacturing process keeps the overall manufacturing relatively simple compared to traditional multi-step processes
Solution Approach 2:
The patent utilizes composite materials by incorporating multiple materials with different properties into the seal cap through three-dimensional printing. This enables the seal cap to exhibit enhanced chemical resistance, corrosion resistance, and temperature resistance by combining materials that excel in each specific property, while the printing process integrates these materials in a single manufacturing step
3Reliability
If multi-layer coreactive compositions are used to enhance seal cap performance, then chemical resistance and conformability are improved, but the manufacturing process time increases
Solution Approach 1:
The patent maintains continuity of useful action by depositing multiple layers of coreactive compositions in a continuous three-dimensional printing process. The layers are deposited sequentially without removing the fastener or the printed structure, and the coreactive compositions cure in situ, eliminating downtime and maintaining continuous productive action throughout the manufacturing process
Solution Approach 2:
The patent applies preliminary action by depositing the coreactive composition layers in their uncured state during the printing process, allowing the structure to be formed first and then cured. This approach enables the multi-layer structure to be built without waiting for each layer to cure, reducing overall manufacturing time while still achieving the desired sealing effectiveness through the coreactive curing mechanism
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enhances the seal cap's performance by providing superior chemical resistance, conformability, and reliability, minimizing voids, and adapting to various fastener shapes and sizes, thus improving durability and sealing effectiveness.
Implementation Method 1
depositing successive layers comprising a first coreactive composition directly onto the fastener by three-dimensional printing
Implementation Method 2
depositing successive layers of a first coreactive composition by three-dimensional printing to form a seal cap shell defining an interior volume; and filling the interior volume with a second coreactive composition
Data Source
AI summary
Methods of fabricating seal caps using three-dimensional printing are disclosed. The seal caps are useful for sealing fasteners.