Composite Seal Coupling Pilot for Refrigerant Leak Resistance
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Solution Overview
Problem
Refrigerant leakage and damage to seals in vehicle cooling systems due to high pressures, temperatures, and vibrations, leading to environmental hazards and increased emissions, with existing seals degrading over time and failing to provide durable connections.
Innovation Solution
A composite seal system using a metal-encased plastic ring with pillar devices to mitigate compressive forces, incorporating a ring-shaped insert and pillars to distribute and manage thermal and mechanical stresses, ensuring consistent sealing performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional seal is used in the cooling system, then the system is simpler and easier to manufacture, but the seal degrades over time due to heat, pressure, and vibration, leading to refrigerant leakage
Solution Approach 1:
The coupling is divided into multiple functional components: an outer coupling body, an inner coupling insert with pillars, and a seal washer. The insert is further segmented into a metal ring encased in plastic material with multiple pillar devices. This segmentation allows each component to perform its specific function optimally while distributing mechanical stresses.
Solution Approach 2:
The insert combines metal ring and plastic material to create a composite structure that leverages the strength and thermal stability of metal with the flexibility and damping properties of plastic. This composite construction enhances overall seal durability under thermal and mechanical loads.
2Reliability
If the seal is subjected to high compressive forces to ensure sealing, then sealing performance improves, but the seal and surrounding materials deform or fail over time
Solution Approach 1:
The pillar devices are designed to absorb and distribute compressive forces before they reach the seal washer and surrounding materials. By providing this cushioning effect in advance, the pillars prevent excessive compression that would lead to material deformation or failure.
Solution Approach 2:
The insert modifies the distribution and magnitude of compressive forces through its structural design. The pillars change the force parameters by distributing load across multiple contact points, reducing peak stresses on the seal and surrounding materials while maintaining adequate sealing pressure.
3Productivity
If the seal is exposed to high temperatures and pressure differentials, then the cooling system operates effectively, but the seal degrades and leaks refrigerant
Solution Approach 1:
The insert acts as an intermediary component between the rigid coupling bodies and the flexible seal washer. It mediates the transmission of thermal and mechanical stresses, protecting the seal from direct exposure to extreme conditions while allowing the cooling system to operate at required temperatures and pressures.
Solution Approach 2:
The composite structure of the insert accounts for thermal expansion differences between materials. The metal ring and plastic material expand at different rates, and the design accommodates these differential expansions to prevent stress concentration and seal degradation under thermal cycling.
4Object-generated harmful factors
If refrigerant leakage is prevented through better sealing, then environmental hazards are reduced, but the coupling structure becomes more complex
Solution Approach 1:
The multi-component segmented design isolates the seal within a protective structure of outer coupling, inner insert, and seal washer. This segmentation creates a dedicated sealing zone that prevents refrigerant leakage while keeping the overall coupling architecture organized and manufacturable.
Solution Approach 2:
The composite insert combines materials with complementary properties to achieve reliable sealing without excessive complexity. The metal-plastic composite provides structural integrity, thermal stability, and stress distribution in a single integrated component that can be manufactured and assembled efficiently.
Data Source
AI summary
A coupling system (100) is disclosed. The system (100) includes an insert (102), an upper part (106) and a flange (104). The insert (102) includes a plurality of pillar devices and has a ring comprised of plastic material. The upper part has a circular shaped opening. The flange has a washer or elastomer seal element (110). Pilot (114 and 116) are a molded plastic that encase the insert ring (102). The washer element is adjacent to and concentric with the circular shaped opening and is comprised of a rubber material. The pillar devices are configured to mitigate force from the upper part to the washer element of the flange. The insert or ring (102) can have an L-shaped profile (502).