Self-Aligning Sliding Air Seal for Leak-Free Removable Modules
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Solution Overview
Problem
Existing air seal systems for removable electronic units are prone to leakage, jamming, misalignment, and are not resistant to corrosive environments, leading to thermal performance issues and vibration-induced phase noise in high-power electronic assemblies.
Innovation Solution
A ruggedized, self-aligning sliding air seal system using a double layer of fluorosilicone material with different durometer values, coated with low friction material, and a wedgelock retention mechanism to provide a reliable, low-friction seal and fixed boundary condition, reducing manufacturing complexity and facilitating easy replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a classic multiple stage vibration isolation system is used, then phase noise performance is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent extracts the vibration isolation function from a complex multi-stage system and implements it through a simple fixed boundary condition at the module-rack interface. The wedge-shaped retention feature directly couples the module to the rack, eliminating the need for multiple isolation stages while achieving the same vibration mitigation effect.
Solution Approach 2:
Instead of using compliant or isolated interfaces to reduce vibration, the patent inverts the approach by creating a rigid fixed boundary condition through the wedge-shaped retention feature. This rigid connection prevents vibration-induced motion rather than isolating from it, achieving phase noise performance through structural rigidity rather than isolation.
2Reliability
If silicone material is used for seals, then sealing effectiveness is improved, but resistance to corrosive environments deteriorates
Solution Approach 1:
The patent uses fluorosilicone material for the resilient seal, which combines the beneficial properties of both fluoroelastomers and silicone rubber. This composite material provides excellent sealing effectiveness like silicone while adding superior resistance to solvents and petro-chemical agents, thus resolving the contradiction between sealing performance and chemical resistance.
3Ease of manufacture
If a tapered surface is used for the seal, then manufacturing cost is reduced, but alignment precision and resistance to jamming deteriorate
Solution Approach 1:
The patent segments the sealing system into distinct functional elements: the wedge-shaped retention feature for alignment and retention, and the resilient seal for sealing. The retention feature includes guide surfaces that positively align the module, separating the alignment function from the sealing function. This segmentation allows the tapered surface to be used for cost-effective manufacturing while the guide surfaces ensure precise alignment and prevent jamming.
4Reliability
If a complex retention method is used, then vibration resistance is improved, but ease of field replacement deteriorates
Solution Approach 1:
The patent employs a dynamic retention system where the resilient seal provides continuous contact pressure to maintain the module in its retained position. This dynamic pressure ensures vibration resistance during operation while allowing simple manual removal when needed, as the module can be easily pried loose by inserting a tool between the module and rack when the seal is compressed.
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 solution effectively prevents air leakage, reduces vibration-induced motion, and enhances the life expectancy of module connectors, while being resistant to a broader range of chemicals and solvents, thus improving thermal performance and phase noise resilience.
Implementation Method 1
coated with a low friction material on the upper elastomeric material to facilitate low sliding friction when an electronics module having a tapered surface is slid over and compresses the seal
Implementation Method 2
a resilient seal member surrounding an opening formed through the base plate and extending from a surface of the base plate
Implementation Method 3
uses a double layer of fluorosilicone material or other environmentally resistant material having two durometer values
Data Source
AI summary
An electronics housing system (S) adapted for electronic devices (D) includes a main chassis unit (M) and at least one removable module (10) mountable with the base unit (M) for supporting electronic circuitry components electro-optically coupled with the base unit (M). The removable module assembly (10) has a main body (12) that includes two opposing mounting edges (14, 16) and a connection edge (18). At least one of the mounting edges (14, 16) of the removable mounting assembly (10) has an opening (20) to receive a cooling air flow (F) into an interior cavity (22) of the main body (12) of the removable module (10). The main chassis (M) has a pair of opposing module mounting assemblies (24, 26) to receive a removable module (10) between the opposing module mounting assemblies (24, 26). The electronics rack wall (24, 26) includes a removable seal plate (32) to provide an air seal.