Monolithic Vacuum Lifter Seal With Continuous Skin Against Delamination

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Solution Overview

Problem

Existing seals for vacuum material lifters delaminate over time due to environmental exposure and compression cycles, leading to loss of vacuum seal integrity and increased maintenance costs, as they are susceptible to liquid absorption and chemical contamination.

Innovation Solution

A monolithic seal with a continuous unbroken outer skin, formed by extruding and curing a thermoset elastomer, eliminating the need for lamination and reducing liquid absorption and chemical penetration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If laminated seals are used to achieve the required thickness, then the seal can provide sufficient compression force, but the seal is prone to delamination and rupture under compression cycles

Engineering Contradiction:

Improvecompression forceVSAvoiddelamination resistance

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent merges multiple layers of sponge rubber into a single monolithic structure through co-extrusion, eliminating the laminated construction that causes delamination. The multi-layer design is achieved by extruding different materials simultaneously rather than bonding separate layers, resolving the contradiction between compression strength and delamination resistance.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent uses composite materials by co-extruding different thermoset elastomers with complementary properties - one layer providing compression resistance and another providing tear strength. This composite approach maintains the required compression force while preventing delamination through integral bonding of the different material layers.

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If open cell surfaces are exposed for maximum bonding area, then the seal can be effectively laminated, but the exposed cells are susceptible to rapid abrasion and wear

Engineering Contradiction:

Improvebonding surface areaVSAvoidabrasion and wear

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent uses a continuous outer skin formed during co-extrusion to enclose the cellular structure. This flexible skin protects the open cells from abrasion and wear while allowing the seal to maintain its compression properties. The skin acts as a protective barrier without compromising the seal's ability to conform to surfaces.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

Instead of exposing open cells to the environment for bonding, the patent inverts the approach by enclosing the open cells within a continuous outer skin. The bonding surface is provided by the outer skin itself rather than by exposed cells, reversing the conventional approach and eliminating wear susceptibility.

Inventive Principle:

Principle #13The other way round (Inversion)

3Area of stationary object

If exposed cells are used on the seal surface, then the seal provides maximum surface area for contact, but the exposed cells quickly absorb liquids causing deterioration

Engineering Contradiction:

Improvecontact surface areaVSAvoidliquid absorption

Core Design Contradiction:

Area of stationary objectVSObject-affected harmful factors

Solution Approach 1:

The continuous outer skin formed during co-extrusion acts as a protective barrier that prevents liquid absorption while maintaining full contact surface area. The skin encloses the cellular structure, allowing the seal to provide maximum contact area without the cells being exposed to liquids that would cause deterioration.

Inventive Principle:

Principle #30Flexible shells and thin films

4Volume of moving object

If pressure sensitive adhesives are used for lamination, then the seal can be fabricated with required thickness, but the bond strength may be less than peel strength causing delamination in service

Engineering Contradiction:

Improveseal thicknessVSAvoidbond strength

Core Design Contradiction:

Volume of moving objectVSStrength

Solution Approach 1:

The patent eliminates adhesive bonding by merging the different layers into a single co-extruded structure. The layers are bonded through the extrusion process itself rather than through separate adhesive application, ensuring bond strength exceeds peel strength and preventing delamination during service.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent replaces the mechanical adhesive bonding system with a thermal bonding system where different thermoset elastomer layers are bonded through the co-extrusion and curing process. This substitution eliminates the weakness of pressure-sensitive adhesives and creates integral bonding that cannot delaminate.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

The monolithic seal prevents delamination, maintains vacuum integrity, and resists permanent compression set, reducing maintenance costs and improving durability against environmental factors.

Implementation Method 1

formed by extruding and curing a thermoset elastomer

Methodology Applied

Scientific EffectExtrusion: Extrusion

Implementation Method 2

formed by extruding and curing a thermoset elastomer

Methodology Applied

Scientific EffectCuring:

Data Source

PatentUS11078051B2Seal for a vacuum material lifter

Publication Date: 2021.08.03 VACUWORX GLOBAL LLC

AI summary

A seal for a vacuum lifter and method of manufacture wherein the seal has a continuous unbroken outer fluid resistant skin of elastomer which forms a boundary around a homogeneous cellular structure with no interior seams or joints.