Monolithic Vibration Isolator Bellows for Hermetic Sealing

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Solution Overview

Problem

Existing vibration isolator assemblies face challenges such as high part counts, assembly complexities, costly fabrication of hermetically sealed bellows, and long cycle times due to manufacturing constraints, limiting their optimal configuration and efficiency.

Innovation Solution

The use of additive manufacturing techniques, specifically direct metal laser sintering (DMLS), allows for the production of vibration isolator assemblies with complex designs featuring variable wall thicknesses and shapes, reducing part counts and manufacturing time while eliminating the need for costly tooling and complex welding processes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If traditional roll-forming or expansive-forming techniques are used to manufacture metallic bellows, then hermetically sealed bellows can be produced, but the geometry is limited to circumferential or round shapes and high part counts are required

Engineering Contradiction:

Improvebellows geometry flexibilityVSAvoidassembly complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent combines multiple traditional components (bellows, end caps, sealing elements, support structures) into a single monolithic structure manufactured via additive manufacturing. This merging eliminates the need for separate hermetic sealing operations and welding processes, while enabling complex geometries including non-circular cross-sections and variable wall thicknesses that cannot be achieved with traditional roll-forming or expansive-forming techniques.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If hermetically sealed metallic bellows are manufactured using traditional techniques, then pressure can be maintained inside the bellows, but fabrication is costly and cycle time is unacceptably high

Engineering Contradiction:

Improvehermetic sealing reliabilityVSAvoidmanufacturing cycle time

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The additive manufacturing process creates the hermetically sealed bellows structure in a single fabrication step, performing the sealing action during the base structure creation rather than as a subsequent operation. The monolithic structure is built with integrated sealing features that are formed simultaneously with the main body, eliminating the need for separate sealing operations and reducing cycle time while maintaining hermetic integrity.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If traditional manufacturing techniques are used for vibration isolator assemblies, then hermetically sealed bellows can be produced, but high part counts and assembly complexities result

Engineering Contradiction:

Improvesealing reliabilityVSAvoidassembly complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges multiple discrete components into a single monolithic structure manufactured via additive manufacturing. The bellows, end caps, sealing elements, and support structures are integrated into one continuous piece, eliminating the need for separate sealing operations and reducing assembly complexity while maintaining hermetic integrity through the monolithic construction.

Inventive Principle:

Principle #5Merging (Combining)

4Ease of manufacture

If conventional bellows manufacturing methods are used, then production can proceed with established processes, but sub-optimal configuration results due to manufacturing constraints

Engineering Contradiction:

Improvemanufacturing process familiarityVSAvoidconfiguration optimization

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The additive manufacturing process enables continuous variation of geometric parameters including wall thickness, cross-sectional shape, and convolute geometry that cannot be achieved with traditional manufacturing methods. The process allows for optimization of these parameters to achieve sub-optimal configurations, such as variable wall thickness for stress distribution and non-circular cross-sections for space optimization, while the layer-by-layer construction maintains manufacturing precision.

Inventive Principle:

Principle #35Parameter changes

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

This approach results in lower-cost, robust, and optimized vibration isolator assemblies with reduced cycle times, enabling faster production and improved reliability by simplifying the manufacturing process and eliminating the limitations of traditional methods.

Implementation Method 1

additive manufacturing techniques, specifically direct metal laser sintering (DMLS)

Methodology Applied

Scientific EffectLaser sintering: Selective Laser Sintering

Data Source

PatentUS10900537B2Vibration isolator assemblies and methods for the manufacture thereof

Publication Date: 2021.01.26 HONEYWELL INTERNATIONAL INC

AI summary

A vibration isolator assembly includes a bellows component, a piston component, a shaft component, and a housing component, wherein at least one of the bellows component, the piston component, the shaft component, and the housing component is formed using additive manufacturing techniques.