Oval Plug Seal With Variable Beads for Bore Offset Compensation
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Solution Overview
Problem
Existing plug & seal technologies are limited by a maximum fluid flow capacity due to requiring a constant circular section for offset compensation, which is inadequate for newer applications like electric vehicles with higher fluid volume demands in constrained spaces, especially when connecting oval-shaped bores.
Innovation Solution
A seal design featuring an oval-shaped tubular insert with variable elastomeric over-mold bead thickness, including a central stopper shoulder, to accommodate offset and maintain sealing capacity for oval-shaped bores.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a constant circular section is used for offset compensation, then sealing capability is maintained, but fluid flow capacity is limited
Solution Approach 1:
The patent transitions from a symmetric circular cross-section to an asymmetric oval cross-section. The oval shape provides a larger cross-sectional area for fluid flow while the asymmetric thickness distribution of the elastomeric over-mold compensates for misalignment. The greater thickness at curved sections and reduced thickness at flat sections maintains sealing capability despite the non-circular geometry, thereby increasing fluid capacity without sacrificing sealing reliability.
Solution Approach 2:
The elastomeric over-mold is designed with non-uniform thickness distribution, creating different local properties throughout the structure. The thicker regions at curved sections provide enhanced sealing and offset compensation, while thinner regions at flat sections reduce material usage and maintain flexibility. This local variation in quality allows the seal to adapt to misalignment while accommodating higher fluid volumes through the oval geometry.
2Quantity of substance
If an oval-shaped bore is connected, then fluid flow capacity is increased, but sealing capability is compromised due to variable gap
Solution Approach 1:
The patent changes the geometric parameters of the seal by adopting an oval cross-section instead of circular. This parameter change increases the cross-sectional area available for fluid flow. Additionally, the elastomeric over-mold thickness is varied as a parameter to compensate for the variable gap created by the oval shape, ensuring consistent sealing pressure and maintaining sealing reliability despite the non-circular geometry.
3Quantity of substance
If a larger cross-section is used to increase fluid flow, then fluid capacity is improved, but offset compensation capability is reduced
Solution Approach 1:
The elastomeric over-mold acts as a flexible element that can deform to accommodate misalignment between connecting bores. The flexible nature of the elastomeric material allows it to conform to offset conditions while maintaining the larger oval cross-section for fluid flow. This flexibility ensures that offset compensation capability is preserved even with the increased fluid capacity provided by the larger cross-section.
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 design compensates for misalignment and maintains sealing capacity by varying bead thickness, enhancing fluid flow capacity in constrained spaces.
Implementation Method 1
An elastomeric over-mold is provided on an exterior of the oval-shaped tubular insert. The elastomeric over-mold includes a pair of raised seal beads each surrounding a respective one of the pair of ends. The pair of raised beads have a first bead thickness in a radial direction along the two flat wall sections and a gradually increasing bead thickness from the ends of the flat wall sections to a center of the two end curved sections.
Data Source
AI summary
A seal for connecting between oval cross-section pipe sections includes an oval shaped tubular insert having two flat wall sections connected to one another by two end curved sections. The oval-shaped tubular insert has a pair of ends with a passage extending through the pair of ends. An elastomeric over-mold is provided on an exterior of the oval-shaped tubular insert. The elastomeric over-mold includes a pair of raised seal beads each surrounding a respective one of the pair of ends. The pair of raised beads have a first bead thickness in a radial direction along the two flat wall sections and a gradually increasing bead thickness from the ends of the flat wall sections to a center of the two end curved sections.