Integrated Static Seal Structure for Variable Gap Extrusion Resistance

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Solution Overview

Problem

Static seals in static applications are prone to gap extrusion due to pressure differences and variable sealing gaps, which can be exacerbated by manufacturing tolerances, uneven connections, and thermal expansion, leading to leaks and reduced effectiveness.

Innovation Solution

A static seal with an integrated support function, comprising a first structure with higher hardness and a second flexible structure, allowing for compression and deformation to compensate for varying sealing gaps, thereby preventing gap extrusion and maintaining sealing efficacy under high pressures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a seal with high hardness is used to resist gap extrusion, then resistance to gap extrusion is improved, but adaptability to variable sealing gaps deteriorates

Engineering Contradiction:

Improveresistance to gap extrusionVSAvoidadaptability to variable sealing gaps

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The seal is divided into two distinct structures: a first structure with higher hardness for gap extrusion resistance and a second structure with lower hardness for adaptability. This segmentation allows each part to fulfill its specific function optimally without compromise.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the seal have different material properties - the first structure uses harder material for support and extrusion resistance, while the second structure uses softer material for adaptation to variable gaps. This local differentiation resolves the contradiction between strength and adaptability.

Inventive Principle:

Principle #3Local quality

2Strength

If separate backing rings are used to prevent gap extrusion, then resistance to gap extrusion is improved, but device complexity increases

Engineering Contradiction:

Improveresistance to gap extrusionVSAvoidnumber of components

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The seal integrates the support function previously requiring separate backing rings into its own structure. The first structure of the seal itself provides the backing support, eliminating the need for additional components and reducing overall device complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The seal performs multiple functions: sealing, gap extrusion resistance, and adaptation to variable gaps. By combining these functions into a single component with integrated structures, the design eliminates separate backing rings and reduces system complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If manufacturing tolerances and connection unevenness are reduced to maintain consistent sealing gaps, then sealing performance is improved, but manufacturing cost and complexity increase

Engineering Contradiction:

Improvesealing performanceVSAvoidmanufacturing tolerance requirements

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The seal uses material hardness as a key parameter to compensate for dimensional variations. The softer second structure deforms to accommodate gap variations caused by manufacturing tolerances and connection unevenness, maintaining sealing performance without requiring tight manufacturing controls.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The flexible second structure acts as a cushion that absorbs and compensates for gap variations before they can compromise sealing performance. This preemptive adaptation allows the seal to tolerate manufacturing variations and connection unevenness.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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 seal effectively bridges large sealing gaps and prevents extrusion by using a harder first structure and a flexible second structure to adapt to variable sealing conditions, ensuring reliable sealing performance even with uneven gaps and high pressures.

Implementation Method 1

The first structure (12) has a higher hardness, in particular Shore A hardness, than the second structure (14)

Methodology Applied

Scientific EffectHardness: Shore Durometer

Implementation Method 2

The second structure (14) at least partially encloses the second end (18) and thus forms a flexible region (20) adjoining the second end (18). The seal is compressible in the flexible region (20) and can therefore compensate for differences in height

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Data Source

PatentUS12523300B2Static seal with integrated support function

Publication Date: 2026.01.13 AEROSTACK GMBH

AI summary

A seal with integrated support function for a static axial seal application in the secondary force flux, for a resulting sealing gap, and with variable height. The seal includes a first structure with a first material, and a second structure with a second material. The first and second structures are connected. The first structure has a higher hardness, or Shore A hardness, than the second structure. The first structure has an elongate form, a first and second end, and is insertable lengthwise into a sealing groove. The second structure at least partially encloses the second end and forms a flexible region adjoining the second end, where the seal is compressible in the flexible region and can compensate for differences in height. The seal provides functional integration with integrated support function with a flexible region for bridging large and variable sealing gaps and a sealing function relating to contacting parts.