Pass-through Seal with Varying Outer Profile for Non-Orthogonal Angles
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Solution Overview
Problem
Existing pass-through seals in vehicles fail to effectively seal components when they are loaded at non-orthogonal angles relative to the structural members, leading to sealing gaps and increased noise or stress on the components.
Innovation Solution
A pass-through seal with multiple portions, where one portion has an outer profile that forms an interference fit with the aperture and another portion is larger than the aperture to prevent it from passing through, allowing the seal to support and align components at predefined angles, ensuring a snug fit and secure sealing regardless of the angle of assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single cut axis seal is used to create interference fit with the opening, then the seal works well when the component is loaded orthogonally to the structural member surface, but the seal creates gaps and increases noise when the component is loaded at non-orthogonal angles
Solution Approach 1:
The seal is divided into multiple segments or portions with different functions. One portion creates the interference fit with the opening while another portion accommodates the component at non-orthogonal angles. This segmentation allows each portion to optimize its function without compromising the other, resolving the contradiction between sealing effectiveness and adaptability to various loading angles.
Solution Approach 2:
Different portions of the seal have different geometric properties and material characteristics tailored to their specific functions. The interference-fit portion has a shape optimized for creating a tight seal with the opening, while the component-supporting portion has a geometry designed to accommodate non-orthogonal loading. This local differentiation of properties allows the seal to simultaneously achieve reliable sealing and adaptability to various angles.
2Ease of manufacture
If a die-cut foam seal with orthogonal outer profile is used, then the seal is simple to manufacture, but the seal cannot properly support components loaded at non-orthogonal angles
Solution Approach 1:
The seal is segmented into portions that can be manufactured using standard die-cutting processes, maintaining manufacturing simplicity. Each segment is designed with specific geometric features that, when assembled, achieve the complex function of supporting components at non-orthogonal angles while maintaining alignment precision.
Solution Approach 2:
The seal incorporates asymmetric geometries in specific portions to accommodate non-orthogonal loading angles. These asymmetric features are integrated into an otherwise symmetric die-cut design, allowing the seal to maintain ease of manufacture while achieving the precision alignment needed for non-orthogonal component support.
3Adaptability or versatility
If a seal with non-orthogonal inner profile is used to accommodate non-orthogonal loading, then the seal supports the component at the correct angle, but the seal creates gaps and increases stress on the component
Solution Approach 1:
The seal is divided into portions with distinct functions: one portion provides the non-orthogonal support geometry while another portion maintains the orthogonal interference fit for sealing. This segmentation allows the seal to accommodate non-orthogonal loading angles without compromising sealing integrity, as each portion optimizes its specific function without creating gaps or excessive stress.
Data Source
AI summary
A pass-through seal may seal a component extending between a first member and a second member in a vehicle. The pass-through seal may define a core opening and have a varying outer profile. The core opening receives the component at a predefined angle relative to an aperture defined by the first member. The core opening supports the component at the predefined angle at one end and has a snug fit with the component at the other end. The varying outer profile is configured to create an interference fit with the aperture defined by the first member at one end and to be larger than the aperture at the other end.