Lattice-Reinforced Elastomer Composites for Peel-Resistant Rigidity
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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 comprising 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 rigidity, then rigidity is improved, but the manufacturing process becomes more complex and costly due to additional surface treatment steps
Solution Approach 1:
The lattice structure and the elastomeric article are combined into a single monolithic component through additive manufacturing. The lattice structure is built directly within the mold cavity, eliminating the need for separate frame formation and insertion steps. This merging of components resolves the technical contradiction by maintaining rigidity enhancement while significantly simplifying the manufacturing process.
Solution Approach 2:
The lattice structure is pre-formed within the mold cavity using additive manufacturing before the elastomer is injected. This preliminary action allows the lattice to be precisely positioned and integrated with the mold geometry, ensuring optimal rigidity support while eliminating subsequent assembly steps and surface treatment requirements.
2Strength
If an internal frame or structure is overmolded with elastomer, then structural support is improved, but peel resistance deteriorates due to elastomer peeling from the frame under tension or compression
Solution Approach 1:
The lattice structure provides a porous, high-surface-area framework that enables extensive mechanical interlocking with the elastomer. The elastomer flows through and around the lattice members, creating a interpenetrating network that prevents peeling. This porous lattice architecture resolves the technical contradiction by maintaining structural support while dramatically improving peel resistance through enhanced bonding surface area.
Solution Approach 2:
The invention creates a composite structure where the rigid lattice framework and the flexible elastomer are integrated at the micro-scale. The lattice members act as reinforcement within the elastomeric matrix, forming a unified composite material system. This composite approach resolves the peeling issue by ensuring continuous bonding between the two materials throughout the interface, rather than at a discrete boundary.
3Ease of manufacture
If traditional overmolding with internal frames is used, then manufacturing is achievable, but manufacturing efficiency deteriorates due to multiple surface treatment steps and higher costs
Solution Approach 1:
The invention replaces traditional mechanical surface treatment processes (such as roughening, coating, or chemical etching) with an additive manufacturing process. The lattice structure is directly built with the required geometric complexity and surface area through layer-by-layer deposition, eliminating the need for separate surface preparation steps. This substitution resolves the technical contradiction by maintaining manufacturability while significantly improving manufacturing efficiency and reducing costs.
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.