Grooved Injection Molded Sealing Element
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Solution Overview
Problem
Injection molded sealing elements exhibit higher leakage and scatter in sealing behavior compared to machined parts, limiting their use in applications like thermal management modules due to lack of a structured surface that effectively reduces leakage paths.
Innovation Solution
Incorporating a grooved surface structure over the periphery of the sealing surface in the injection molding process, replicating the sealing behavior of machined parts without additional finishing steps, using techniques like erosion, etching, or lasers to achieve a microstructured surface with low roughness values, suitable for various plastics including fluoroplastics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If injection molding process is used to manufacture sealing elements, then manufacturing cost and productivity are improved, but sealing precision and tightness deteriorate due to random surface structure
Solution Approach 1:
The injection molding tool is pre-equipped with structuring elements (grooves, ribs, or patterns) on the sealing surface that directly form the desired surface structure during the injection molding process itself, eliminating the need for subsequent machining operations and ensuring consistent sealing precision from the start
Solution Approach 2:
The surface structure parameters (roughness, groove depth, pattern geometry) are optimized within the injection molding process to achieve the desired sealing performance, transforming the random nubbed structure into a controlled microstructure that provides both productivity and sealing precision
2Manufacturing precision
If machining process is used to manufacture sealing elements, then sealing precision is improved, but manufacturing cost and time increase
Solution Approach 1:
The required surface structure for sealing is created during the injection molding process itself through integrated structuring elements in the mold, performing the sealing surface preparation in advance and eliminating the need for separate machining operations
Solution Approach 2:
The injection molding process is combined with surface structuring by integrating structuring elements directly into the mold cavity, merging two previously separate processes (molding and surface preparation) into one efficient operation that maintains both productivity and sealing precision
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 grooved surface structure significantly improves the tightness of injection molded sealing elements, achieving sealing performance comparable to machined parts, with reduced leakage paths and low friction, enabling their use in demanding applications without the need for costly machining.
Implementation Method 1
a groove structure is produced by means of erosion, etching, or lasers
Implementation Method 2
a groove structure is produced by means of erosion, etching, or lasers
Implementation Method 3
a groove structure is produced by means of erosion, etching, or lasers
Data Source
AI summary
A sealing element made of a plastic, which is embodied to seal against an actuator and consists of a plastic or resin that can be handled in an injection molding process. In order to significantly improve a sealing tightness of injection molded sealing elements made of a plastic, according to the invention the sealing element, as a direct product of an injection molding process, is provided with a structure in the form of a groove in the sealing surface, which groove is distributed over the periphery of the sealing surface.