Monolithic Electroplating Seal With Low-Porosity Additive Surface
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Solution Overview
Problem
Conventional electroplating systems face challenges in producing seals with robust, low-porosity, and cost-effective surfaces that are reactive with electrolytes, often requiring expensive machined materials and adhesives, while additive manufacturing methods result in coarse and porous surfaces.
Innovation Solution
The development of monolithic electroplating seals using additive manufacturing, featuring an external and internal seal member with a porosity of less than 10 vol.%, formed from thermoplastic polymers and fillers, and a deformable thermoplastic elastomer, which are integrated to create a unitary body without adhesives or metal support, allowing for improved surface finish and reduced porosity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional machined materials and specialized seal components are used, then reliability and low porosity are improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines multiple seal components (external seal member, internal seal member, and deformable seal member) into a single monolithic electroplating seal structure. This integration eliminates the need for separate components and adhesives while maintaining the sealing function, directly resolving the contradiction between reliability and device complexity.
Solution Approach 2:
The patent employs composite materials in the additive manufacturing process, using polymer layers with fillers (such as glass-filled polypropylene) to achieve low porosity and appropriate mechanical properties. This allows the single integrated structure to meet reliability requirements without requiring complex multi-material assemblies.
2Ease of manufacture
If additive manufacturing is used to produce seals, then manufacturing cost and ease of manufacture are improved, but surface quality and porosity worsen
Solution Approach 1:
The patent applies different surface quality requirements to different regions of the seal. The exterior surface that contacts the electrolyte is designed with specific smoothness requirements (Ra ≤ 3.2 µm), while internal surfaces can have additive manufacturing characteristics. This selective approach allows additive manufacturing to be used while meeting critical surface quality requirements.
Solution Approach 2:
The patent modifies additive manufacturing parameters including using fine powder materials (5-50 µm particle size), controlling layer thickness (0.05-0.5 mm), and applying post-processing techniques like tumbling or blasting to achieve the required surface finish. These parameter changes enable additive manufactured seals to meet manufacturing precision requirements.
3Reliability
If polymer layers with low porosity are used for the exterior surface, then reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The patent uses homogeneous polymer materials (such as polypropylene) for the exterior surface layers that contact the electrolyte. This uniform material selection simplifies the layer structure while ensuring consistent low porosity and reliable electrolyte barrier properties, resolving the contradiction between reliability and manufacturing complexity.
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 solution enables the production of electroplating seals with enhanced surface properties, reduced porosity, and cost-effectiveness, eliminating the need for adhesives and metal supports, while maintaining robustness and compatibility with electrolytes.
Implementation Method 1
The exterior surface is formed from at least one polymer layer having a porosity of less than or about 10 vol. %
Implementation Method 2
The internal seal member includes a deformable thermoplastic elastomer
Data Source
AI summary
The present technology includes monolithic electroplating seals, such as electroplating seals formed utilizing additive manufacturing. Seals include an external seal member and an internal seal member. The external seal member includes an inner annular radius, an outer annular radius, and an external seal member body defined between an exterior surface and an interior surface opposite the exterior surface. The exterior surface is formed from at least one polymer layer having a porosity of less than or about 10 vol. % and the external seal member body includes a filler. The internal seal member is formed integrally with and extends along at least a portion of the interior surface of the external seal member from the inner annular radius towards the outer annular radius. The internal seal member includes a deformable thermoplastic elastomer.