Monolithic Seal Structure for Leak-Resistant Additive Assemblies
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Solution Overview
Problem
Conventional mechanical seals require a lengthy manufacturing and assembly process, are prone to leak paths due to environmental changes and aging, and often rely on separate components that can become dislodged from the interface.
Innovation Solution
A seal structure is integrally formed within a body using additive manufacturing, featuring a protruding portion that deforms to create a seal between the body and a contact member, eliminating the need for separate components and reducing leak paths by being seamlessly secured.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate mechanical seal (e.g., O-ring gasket) is used to seal the interface between two objects, then the seal can be compliant and deformable to fill the space, but the manufacturing and assembly process becomes lengthy and complex
Solution Approach 1:
The seal structure is merged with the body to form an integral monolithic object. The protruding portion of the outer surface of the body itself forms the seal, eliminating the need for a separate seal component. This integration reduces the number of parts and simplifies the manufacturing and assembly process while maintaining sealing effectiveness.
Solution Approach 2:
The body serves multiple functions: it provides structural support and simultaneously forms the seal through its protruding portion. The single monolithic object performs both structural and sealing roles, reducing device complexity while maintaining reliability.
2Adaptability or versatility
If a separate mechanical seal is affixed to an object, then the seal can be replaced or adjusted, but leak paths may form between the seal and the object due to environmental conditions, aging, or displacement
Solution Approach 1:
By merging the seal structure with the body into a monolithic object, the interface between separate components is eliminated. This prevents leak paths from forming at the seal-body interface due to environmental conditions, aging, or displacement, while the seal remains functional through the protruding portion's deformation capability.
3Reliability
If a compliant seal material is used to absorb vibrations and reduce relative movement, then the seal effectiveness improves, but the seal may become dislodged or deform excessively over time
Solution Approach 1:
The seal structure is integrated into the body as a monolithic object, preventing the seal from becoming dislodged. The protruding portion maintains its position relative to the body while still being able to deform locally to absorb vibrations and maintain sealing contact.
Solution Approach 2:
The protruding portion has localized compliance at the sealing surface to absorb vibrations and deform to fill gaps, while the overall structure maintains stability. The seal structure can have varying material properties or geometries at different locations to optimize both compliance and stability.
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 provides a cost-effective, efficient seal that withstands harsh conditions and maintains integrity over time, preventing material ingress and egress while reducing relative movement between objects.
Implementation Method 1
The protruding portion may be configured to engage and at least partially deform into the channel in response to a load generated by pressing an outer surface of the protruding portion against a contact surface of a contact member
Implementation Method 2
The channel may be filled with a biasing agent. The biasing agent may be configured to respond to a load being applied to the protruding portion by resisting such deformation by a determined amount
Data Source
AI summary
A seal structure can include a protruding portion of an outer surface of a body. An inner surface of the protruding portion may define at least a portion of a channel. The protruding portion may be configured to engage and at least partially deform into the channel in response to a load generated by pressing an outer surface of the protruding portion against a contact surface of a contact member to provide a seal between the body and the contact member. The seal structure may be integrally formed within the body as a monolithic object. The body may face towards the contact surface of the contact member during operation of the seal structure. A method may include forming a monolithic body with an integral seal structure by additively fusing material so that the body has an outer surface facing towards a contact surface of a contact member.