High-Pressure Connection Seal Design
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Solution Overview
Problem
High-pressure connections for gaseous and liquid media, particularly in hydrogen refueling, face challenges with leak-free sealing at pressures above 700 bar due to deformation of PTFE sealing rings under constant pressure, leading to potential accidents and environmental hazards.
Innovation Solution
A two-part seal design featuring a harder PEEK seal carrier and a softer PTFE seal insert, providing a double seal mechanism that adapts to high pressures, preventing gas or liquid escape by utilizing the modulus of elasticity difference between the materials to maintain sealing integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If PTFE sealing rings are used for high-pressure connections, then cold resistance is improved, but deformation under constant pressure (cold flow) worsens sealing reliability
Solution Approach 1:
The sealing ring is divided into two separate components: a PTFE seal insert providing cold resistance and a PEEK seal carrier providing structural stability. This segmentation allows each material to perform its optimal function without the drawbacks of the other.
Solution Approach 2:
The invention uses a composite sealing structure combining PTFE (softer, cold-resistant) and PEEK (harder, pressure-resistant) materials. The PTFE seal insert is housed within the PEEK seal carrier, creating a composite system that leverages the advantages of both materials.
2Reliability
If PTFE compounds with carbon or glass fibers are used to improve pressure resistance, then deformation under pressure is reduced, but sealing adaptability worsens
Solution Approach 1:
Different regions of the sealing system have different material properties: the PTFE seal insert provides cold resistance and conformability, while the PEEK seal carrier provides structural strength and pressure resistance. Each material is placed where its specific properties are most needed.
Solution Approach 2:
Instead of adding fillers to PTFE, the invention uses a composite structure of two pure materials (PTFE and PEEK) working together. The PEEK carrier maintains pressure resistance without compromising the PTFE insert's ability to adapt to sealing surfaces.
3Device complexity
If a single-material seal is used, then device complexity is reduced, but sealing performance at high pressure worsens
Solution Approach 1:
The seal is segmented into an inner PTFE seal insert and an outer PEEK seal carrier. This segmentation enables high-pressure sealing performance by combining materials with complementary properties, while the modular design keeps manufacturing and assembly relatively simple.
Solution Approach 2:
The composite structure of PTFE and PEEK materials provides superior sealing performance at high pressures compared to single-material seals, while maintaining a relatively simple overall design that can be manufactured and assembled with standard processes.
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 ensures a reliable, long-term leak-free sealing at high pressures, enhancing safety and preventing accidents and environmental damage, suitable for various applications including vehicle refueling and industrial plants.
Implementation Method 1
the seal insert consists of a softer plastic, in particular PTFE
Implementation Method 2
the PTFE sealing rings mostly used are cold-resistant, but have the negative property of deforming under constant pressure (so-called 'cold flow')
Implementation Method 3
The sealing piston 3 is in this case acted upon by a spring 3a, ie pressed to the right here
Data Source
Figure 1~2
AI summary
The invention relates to the simple and safe construction of a high-pressure connection (1) for transferring gaseous and/or liquid media, in particular for the refuelling of vehicles with hydrogen. According to the invention, the high-pressure connection (1) comprises a housing (2) with a media passage (P) and a leaktight piston (3) of which the front end is disposed in a sealing manner with respect to an annular seal. The seal (4) has a seal support (4a) in which is inserted a sealing insert (4b), the sealing support (4a) consisting of a harder plastics and the sealing insert (4b) consisting of a softer plastics.