Supported Elastomeric Foam Seal for Low Clamping Pressure
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Solution Overview
Problem
Current sealing technologies, such as liquid polysulfide materials and dry sealing materials like O-rings and gaskets, face challenges in durability, chemical resistance, and ease of installation, particularly in harsh environments and varying interface profiles, with limitations in cold temperatures and conformability.
Innovation Solution
A supported elastomeric foam with a foamed region and a reinforcement region, featuring a porous layer imbibed with elastomer, providing a gas-tight seal at low clamping pressures and resisting chemical attacks, formed by combining an elastomer with a foaming agent and a porous layer, such as ePTFE or PEEK, to create a composite structure that compresses effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If liquid polysulfide sealant is used to seal interfaces, then conformability to interface geometries is improved, but installation time and complexity increase due to long curing periods and careful mixing requirements
Solution Approach 1:
The patent changes the physical state parameter of the sealing material from liquid (polysulfide sealant) to solid foam form. This parameter change allows the material to conform to interface geometries through compression rather than liquid flow and curing, eliminating the long curing time while maintaining adaptability to various interface profiles
Solution Approach 2:
The patent uses a composite structure consisting of a foam core surrounded by a skin layer. The foam core provides conformability and compression, while the skin layer provides chemical resistance and structural integrity. This composite approach resolves the contradiction by combining the advantages of different material forms without the drawbacks of either pure liquid sealant or traditional dry seals
2Reliability
If traditional dry sealing materials like O-rings and gaskets are used, then chemical resistance is improved, but conformability to varying interface profiles deteriorates
Solution Approach 1:
The patent creates a composite structure where a foam core provides conformability to interface geometries through its compressible cellular structure, while an outer skin layer made of chemically resistant material provides protection against chemical attack. This composite design allows the sealing material to simultaneously achieve both conformability and chemical resistance, resolving the contradiction between these two properties
Solution Approach 2:
The patent applies different material properties to different regions of the sealing element. The inner foam core has high conformability and compressibility, while the outer skin layer has high chemical resistance. This local differentiation of material qualities allows each region to perform its specific function optimally, resolving the contradiction between conformability and chemical resistance
3Reliability
If polysulfide liquid sealant is applied between connected parts, then sealing effectiveness is improved, but removal and adjustment capability deteriorates as the seal cannot be removed without breaking the seal
Solution Approach 1:
The patent changes the state of the sealing material from liquid (which cures irreversibly) to a compressible solid foam that can be mechanically removed. The foam maintains sealing effectiveness through compression and elastic recovery, but can be easily removed by decompression and physical extraction without breaking the seal structure, enabling adjustment and repair operations
4Strength
If reinforcement is added to improve foam structural integrity, then resistance to mechanical stress is improved, but compression capability deteriorates due to reduced compressibility
Solution Approach 1:
The patent uses a composite structure with a foam core and a thin skin layer. The foam core maintains high compressibility for sealing capability, while the skin layer provides structural integrity and resistance to mechanical stress. The skin layer is designed to be thin enough to allow compression of the underlying foam while providing sufficient strength to prevent structural failure, thus resolving the contradiction between strength and compression capability
Solution Approach 2:
The patent applies different mechanical properties to different regions: the inner foam core has high compressibility and low stiffness to enable sealing under compression, while the outer skin layer has high strength and stiffness to resist mechanical stress and maintain structural integrity. This local differentiation resolves the contradiction by allowing each region to optimize for its specific function
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 supported elastomeric foam achieves a gas-tight seal with low clamping pressures, maintains integrity under severe mechanical stress, and prevents fluid ingress across a wide temperature range, while being chemically stable and easily installable, offering improved durability and resistance to chemical attacks.
Implementation Method 1
the reinforcement region includes a porous layer having an interconnected network of pores at least partially imbibed with the elastomer
Implementation Method 2
The supported elastomeric foam achieves a gas-tight seal with low clamping pressures
Implementation Method 3
resisting chemical attacks
Data Source
AI summary
A supported elastomeric foam (100) includes an elastomeric matrix (102) formed of an elastomer and including a reinforcement region (104) and a foamed region (106). The foamed region includes gas filled cells (108) in the elastomer, and the reinforcement region includes a porous layer (204) having an interconnected network of pores at least partially imbibed with the elastomer. The foam can include an adhesive at a surface of the foam. A compressible seal (802) including a compressible body, which can be elastomeric foam, can also include a pattern of discontinuous adhesive regions about which the compressible body can deform to form a sea. The supported elastomeric foam can form a gas tight seal in an interface when placed under minimal compression.