Sensor-Integrated Seal Structure to Prevent Delamination
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Solution Overview
Problem
In hydroelectric power stations, existing seal monitoring methods are not practical for detecting defects or aging without shutting down or disassembling the installation, and known solutions weaken the seal's structure.
Innovation Solution
A seal with integrated sensors adhered to deformable material, using a stack of adhesion primer films and elastomer-impregnated fabric for secure attachment, allowing real-time monitoring of wear and efficiency without compromising mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a sensor is integrated into the seal structure, then monitoring capability is improved, but structural strength deteriorates
Solution Approach 1:
The sensor is merged with the seal structure by embedding it within the elastomeric material and securing it with adhesive layers. The sensor becomes an integrated part of the seal, allowing monitoring functionality to be combined with the sealing structure without requiring separate mounting that would compromise strength.
Solution Approach 2:
The seal employs a composite structure consisting of the elastomeric seal material, adhesive layers, and sensor components. This composite construction allows the sensor to be embedded while maintaining the overall structural integrity through the bonding action of the adhesive layers that distribute stresses across the interface.
2Reliability
If the sensor is adhered to the deformable material, then monitoring function is improved, but delamination risk increases
Solution Approach 1:
The adhesive layers change the interface properties between the sensor and deformable material, creating a transition zone with optimized bonding characteristics. The adhesive material parameters (viscosity, curing properties, bonding strength) are selected to ensure stable adhesion that accommodates the deformable nature of the seal material while preventing delamination.
3Productivity
If monitoring is implemented without shutdown, then operational continuity is improved, but measurement accuracy may deteriorate
Solution Approach 1:
The seal performs self-monitoring through the integrated sensor that detects wear and operational conditions directly during service. The sensor continuously measures parameters such as thickness, stress, or deformation states, allowing the seal to provide its own diagnostic information without requiring external inspection or system shutdown.
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
Enables real-time monitoring of seal condition and efficiency without shutdown or disassembly, maintaining robustness and preventing delamination, thus optimizing maintenance and reducing replacement costs.
Implementation Method 1
at least one film (6, 8) of an adhesion primer, which covers at least a portion of the surface of the sensor while being in contact with the surface of the sensor; the portion of fabric impregnated with the second elastomer, which covers the film of the adhesion primer while being in contact with this film (6, 8) of the adhesion primer
Data Source
Figure 1~2
Figure 3
AI summary
A seal (10) comprises at least one portion made of a deformable material having a sealing function, and at least one sensor (2) which is incorporated in the seal, being stuck to the deformable material having a sealing function. For an adhesion effect between the sensor and the deformable material, a stack comprising a film of adhesion primer (6, 8) in contact with the surface of the sensor, a portion of fabric (4, 5) impregnated with an elastomer, and another film of adhesion primer (7, 9) for contact with the deformable material is provided. Cohesion of the seal and resistance to delamination are provided by the adhesion between the sensor (2) and the deformable material having a sealing function. The sensor may be a pressure sensor and the seal may be intended for a valve of a hydroelectric plant.