Embedded Sensor Polymer Seal for Performance Decay Detection
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Solution Overview
Problem
Existing seal systems lack a cost-effective method to measure the decay or change in sealing performance during use, leading to potential failures that can result in maintenance issues or hazardous situations.
Innovation Solution
A seal system comprising a polymer seal with an embedded measurement device and evaluation unit that measures sealing performance aspects, generates signals, and determines the seal's capability, using sensors and continuous material compositions to monitor changes in sealing performance, allowing for timely replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a seal system includes embedded measurement devices and evaluation units to monitor sealing performance, then measurement precision and reliability are improved, but device complexity increases
Solution Approach 1:
The measurement device is embedded within the seal structure itself, with sensors and evaluation units integrated into the seal layers. This nesting approach allows the measurement system to be contained within the existing seal footprint, minimizing additional space requirements and reducing overall system complexity while maintaining measurement precision.
Solution Approach 2:
The patent combines multiple functions into integrated components: the seal structure merges with measurement sensors, the evaluation unit consolidates data processing functions, and the warning system integrates with existing control mechanisms. This merging reduces the number of separate components and simplifies the overall system architecture.
2Reliability
If continuous monitoring of seal performance is implemented, then reliability is improved by detecting degradation early, but use of energy increases due to continuous operation of measurement and evaluation systems
Solution Approach 1:
The evaluation unit operates periodically rather than continuously, assessing seal performance at predetermined intervals or when triggered by specific conditions. This periodic operation maintains reliability by detecting degradation trends while significantly reducing energy consumption compared to continuous monitoring.
Solution Approach 2:
The system performs preliminary assessments at scheduled intervals to detect early signs of degradation before failure occurs. By conducting measurements in advance and establishing baseline performance characteristics, the system can predict potential failures without requiring continuous energy-intensive monitoring.
3Measurement precision
If embedded sensors and evaluation units are integrated into the seal, then measurement precision is improved, but manufacturing precision requirements increase
Solution Approach 1:
The seal structure is divided into functional segments: the base seal layer, embedded sensor modules, and evaluation unit components. This segmentation allows each component to be manufactured and tested separately with standard tolerances, then assembled together, reducing the overall manufacturing precision requirements compared to creating a fully integrated monolithic structure.
Solution Approach 2:
The patent introduces intermediary elements such as sensor housings, adhesive layers, and alignment features that facilitate the integration of measurement devices into the seal structure. These intermediaries accommodate normal manufacturing variations and ensure proper positioning without requiring extreme precision in the base seal components.
Data Source
AI summary
A sealing system for sealing between two members includes a polymer seal disposed between the two members, a measurement device, and an evaluation unit. The measurement device is at least partially disposed within the polymer seal, is configured for measuring an aspect of the polymer seal indicating sealing performance of the polymer seal, and is configured for creating a signal corresponding to a measured aspect of the polymer seal. The evaluation unit is configured for evaluating the signal corresponding to the measured aspect of the polymer seal and for determining a sealing performance capability of said polymer seal.