Elastomeric Sealing for Industrial Automation I/O Modules
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Solution Overview
Problem
Industrial automation input output modules using potting compounds face issues with disassembly, repair, weight, and recycling due to their inability to be disassembled and reconfigured, and the presence of potting compounds hinders environmental sealing and recycling.
Innovation Solution
An industrial automation input output module utilizing a one-piece elastomeric main seal that provides fluid-tight seals between housing members and connectors, eliminating the need for potting compound, with a light-pipe portion for visual indicators and O-ring seals for connectors, ensuring IP69/IP67 ingress protection standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If potting compound is used to seal the module, then ingress protection is improved, but disassembly and repair capability deteriorates
Solution Approach 1:
The sealing system is segmented into multiple independent sealing elements (O-rings, gaskets, seals) positioned at different interfaces (housing joints, connector openings, cable access points). Each sealing element can be independently removed and replaced, enabling disassembly and repair while maintaining ingress protection when assembled.
Solution Approach 2:
Elastomeric sealing elements (O-rings, gaskets, and seals) are used instead of rigid potting compound. These flexible elements can be compressed to create seals during assembly, then easily removed by releasing the compression, allowing disassembly and reconfiguration while maintaining environmental protection.
2Reliability
If potting compound is used to seal the module, then ingress protection is improved, but weight increases
Solution Approach 1:
Thin elastomeric sealing elements (O-rings, gaskets, seals) replace dense potting compound. These flexible membranes provide effective sealing at minimal thickness, dramatically reducing the weight contribution of sealing components while maintaining IP69/IP67 ingress protection.
3Reliability
If potting compound is used to seal the module, then ingress protection is improved, but manufacturing complexity increases due to curing processes
Solution Approach 1:
The curing process and associated complexity are extracted from the sealing system by replacing chemical-based potting compound with mechanical sealing elements. The seals are installed in compressed states and maintain sealing through mechanical force alone, eliminating curing steps, heat application, and extended processing times.
Solution Approach 2:
Chemical bonding mechanisms (potting compound curing) are replaced with mechanical sealing mechanisms (compressed elastomeric elements). The sealing function is achieved through mechanical compression and elastic deformation rather than chemical polymerization, simplifying the manufacturing process.
4Reliability
If potting compound is used to seal the module, then ingress protection is improved, but adaptability deteriorates
Solution Approach 1:
The sealing system is divided into discrete, replaceable components at each interface and opening. This segmentation allows different sealing elements to be selected and configured for specific application requirements while maintaining ingress protection, enabling adaptability across different module configurations.
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 solution allows for modular reconfiguration and recycling while maintaining high resistance to contaminants, eliminating the need for curing processes and reducing weight, thus enhancing operational efficiency and environmental sealing.
Implementation Method 1
A one-piece elastomeric main seal is installed in a groove of the outer housing member... The main seal includes: (i) a lateral seal portion that provides a fluid-tight seal... and, (ii) a face seal portion located in the groove that provides a fluid-tight seal
Implementation Method 2
O-ring seals for connectors, ensuring IP69/IP67 ingress protection standards
Data Source
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AI summary
An industrial automation input output module is protected against ingress of water, oil, debris, dirt and other contaminants without use of a potting compound. An elastomeric main seal provides a fluid-tight connection between inter-fitted inner and outer housing members that define a housing of the module. The one-piece main seal includes an integral light pipe portion with at least one light pipe that communicates light from an LED or other light source to a visual indicator opening in the housing, and the light pipe portion is also sealed to the housing to prevent ingress of contaminants through the visual indicator opening. Connectors pass through a wall of the housing and connector seals are used to prevent ingress of contaminants between the connectors and the housing. The connectors are also secured against rotation relative to the housing.