3D-Printed Seal Cap Structure for Complex Fastener Sealing
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Solution Overview
Problem
Existing seal cap technologies fail to provide optimal chemical resistance, corrosion resistance, hydrolytic stability, low temperature flexibility, and high temperature resistance while efficiently dissipating electrical charge, especially when applied to fasteners with complex geometries.
Innovation Solution
The method involves depositing successive layers of a coreactive composition using three-dimensional printing to form a seal cap shell and filling the interior volume with another coreactive composition, allowing for a robust and customizable seal that conforms to the fastener's geometry, enhancing chemical bonding and interface integrity.
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 provide optimal chemical resistance, corrosion resistance, and adaptability to complex fastener geometries
Solution Approach 1:
The patent applies parameter changes by transitioning from traditional manufacturing methods to additive manufacturing, enabling precise control over seal cap geometry, material composition, and layer structure to achieve optimal performance for complex fastener shapes
Solution Approach 2:
The patent utilizes composite materials by combining a coreactive composition that cures to form the seal cap shell with a filling composition, creating a multi-material structure that enhances both chemical resistance and adaptability to complex geometries
2Ease of manufacture
If a single-material seal cap is used, then manufacturing is simpler, but the seal cap cannot simultaneously provide chemical resistance, flexibility, and electrical charge dissipation
Solution Approach 1:
The patent applies segmentation by dividing the seal cap into two functional parts: a shell formed from a coreactive composition and an interior filled with a filling composition, allowing each part to provide different properties while maintaining manufacturing efficiency
Solution Approach 2:
The patent implements local quality by using different materials for different regions of the seal cap - the shell provides structural integrity and chemical resistance, while the filling composition provides flexibility and electrical charge dissipation, optimizing performance in each specific location
3Productivity
If conventional sealing methods are used, then production time is reduced, but the seal cap lacks durability and effectiveness in demanding conditions
Solution Approach 1:
The patent applies parameter changes by utilizing the coreactive composition's ability to cure rapidly while maintaining durability, achieving both short production time and long service life through controlled chemical reaction parameters
Solution Approach 2:
The patent uses composite materials where the combination of the coreactive shell and filling composition creates a synergistic effect that enhances durability and effectiveness in demanding conditions while maintaining efficient production
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 results in seal caps that provide superior chemical resistance, flexibility, and durability, effectively sealing fasteners from environmental factors and electrical charges, even in demanding conditions like aerospace use.
Implementation Method 1
coreactive composition... compounds capable of reacting with compounds in the other coreactive composition to form a cured polymer network
Data Source
Figure 1A~1B
Figure 2A~2C
Figure 3A~3D
AI summary
Methods of fabricating seal caps using three-dimensional printing are disclosed. The seal caps are useful for sealing fasteners.