Lattice-Reinforced Elastomer Structure for Peel-Resistant Gaskets
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Solution Overview
Problem
Molded elastomeric articles often lack rigidity and exhibit peeling issues when under tension or compression due to the absence of internal reinforcement, and current manufacturing methods are inefficient and costly.
Innovation Solution
A composite article featuring a lattice structure formed by additive manufacturing, integrated with an elastomeric section, where the lattice provides enhanced rigidity and bonding surface area, allowing for improved peel resistance and manufacturing efficiency by eliminating the need for surface treatment during overmolding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If an internal frame or structure is formed and inserted within a mold to provide additional rigidity, then rigidity is improved, but the manufacturing process becomes more complex and costly due to additional steps including surface treatment
Solution Approach 1:
The patent combines the internal frame structure and the elastomeric material into a single monolithic component formed by additive manufacturing. The lattice structure is directly built with the elastomer material, eliminating the need for separate frame fabrication, assembly, and surface treatment steps. This merging of components resolves the technical contradiction by maintaining rigidity through the lattice design while dramatically simplifying the manufacturing process.
Solution Approach 2:
The patent changes the manufacturing method from traditional multi-step processes (frame fabrication, surface treatment, assembly, overmolding) to additive manufacturing. This parameter change in the manufacturing process enables direct formation of the lattice structure with integrated elastomeric material, reducing process complexity while maintaining the rigidity benefits of the internal frame.
2Reliability
If surface treatment is applied to the internal frame before overmolding to enhance adhesion, then peel resistance is improved, but manufacturing time and cost increase
Solution Approach 1:
The patent extracts and eliminates the surface treatment step from the manufacturing process. By using additive manufacturing to directly form the lattice structure with integrated elastomeric material, the need for separate surface treatment to enhance adhesion is removed. The monolithic formation process inherently creates strong bonding without requiring additional surface preparation steps, thus improving peel resistance while reducing manufacturing time.
3Adaptability or versatility
If traditional overmolding process is used with separate frame and elastomer, then manufacturing flexibility is maintained, but peel resistance deteriorates due to poor adhesion between frame and elastomer
Solution Approach 1:
The patent uses composite materials by combining the lattice structure material with elastomeric material in a monolithic additive manufacturing process. This composite approach creates inherent bonding between the structural and elastomeric portions, eliminating the adhesion problems associated with traditional overmolding of separate components. The lattice structure and elastomer are formed as one integrated piece, ensuring strong interfacial bonding while maintaining manufacturing flexibility.
Data Source
AI summary
A composite article includes a lattice and an elastomeric section. The lattice includes a plurality of members that form an open-mesh frame defining a plurality of voids between the adjacent members of the frame. The elastomeric section is formed of an elastomer that is disposed about the lattice and within the voids of the lattice. The composite article may be a circular gasket, a gasket with a grip, a rectangular gasket, a vessel cap, a flask stand, and a handle for a hand tool.