3D-Printed Chemically Resistant Seals for Non-Planar Surfaces

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Solution Overview

Problem

Chemically resistant sealing components with complex shapes are difficult and expensive to fabricate, especially when used to seal non-planar surfaces and accommodate changes in surface positions.

Innovation Solution

The method involves depositing successive layers of a coreactive composition using three-dimensional printing and curing them to create a chemically resistant sealing component with fracture energy similar to that of an individual layer, ensuring robust bonding and mechanical strength.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If sealing components are prefabricated to seal complex non-planar surfaces, then sealing effectiveness is improved, but manufacturing difficulty and cost increase significantly

Engineering Contradiction:

Improvesealing effectivenessVSAvoidmanufacturing difficulty

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The sealing component is fabricated using additive manufacturing by depositing successive layers of curable composition, dividing the manufacturing process into discrete layers that can be built incrementally. This segmentation enables complex non-planar shapes to be manufactured without traditional tooling, reducing manufacturing difficulty while maintaining sealing effectiveness.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention transitions from traditional planar sealing component manufacturing to three-dimensional additive manufacturing. By building the sealing component layer-by-layer in three dimensions, the process can accommodate complex non-planar surfaces and geometric variations that would be difficult or expensive to manufacture using conventional methods.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Adaptability or versatility

If sealing components are prefabricated with complex shapes, then ability to accommodate non-planar surfaces is improved, but manufacturing cost increases

Engineering Contradiction:

Improveability to accommodate non-planar surfacesVSAvoidmanufacturing cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The additive manufacturing process serves multiple functions: it creates complex geometries, accommodates non-planar surfaces, and reduces manufacturing costs simultaneously. The same layer-by-layer deposition process that enables geometric complexity also eliminates the need for expensive tooling and assembly operations required by traditional manufacturing methods.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The invention changes the manufacturing parameters from traditional subtractive or formative processes to additive layer-by-layer construction. This parameter change enables cost-effective production of complex shapes by eliminating tooling costs, reducing material waste, and allowing for design flexibility without proportionally increasing manufacturing cost.

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If successive layers are deposited using three-dimensional printing, then complex shapes can be fabricated, but bonding strength between layers may be compromised

Engineering Contradiction:

Improvefabrication capabilityVSAvoidbonding strength between layers

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The sealing component is constructed as a composite structure with multiple successive layers of curable composition. Each layer is deposited and cured to form a bonded interface with the previous layer, creating a multi-layer composite structure. The use of compatible curable compositions and controlled curing processes ensures strong interlayer bonding while maintaining the ability to fabricate complex three-dimensional shapes.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The additive manufacturing process maintains continuous bonding action between layers through successive deposition and curing cycles. Each new layer is deposited onto the previously cured layer and then cured in place, ensuring continuous bonding throughout the structure. This continuous process prevents weak interfaces that might occur with discrete assembly operations.

Inventive Principle:

Principle #20Continuity of useful action

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

The method enables the fabrication of sealing components with consistent mechanical properties and chemical resistance, accommodating non-planar surfaces and changes in surface positions, providing a robust environmental seal.

Implementation Method 1

depositing successive layers of a coreactive composition in a predetermined shape using three-dimensional printing; and curing the deposited coreactive composition

Methodology Applied

Scientific EffectPolymerization: Photopolymerisation

Data Source

PatentUS20260008231A1Methods of making chemically resistant sealing components

Publication Date: 2026.01.08 PPG INDUSTRIES OHIO INC

AI summary

Sealing components having complex shapes and smooth surfaces are may be fabricated using coreactive three-dimensional printing. More specifically the invention relates to chemically resistant sealing components and methods of making said sealing components using three-dimensional printing, and that may be used in vehicle applications.