Swaged Tube Stub Weld Caps for High-Temperature Fluid Sealing
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Solution Overview
Problem
Existing fluid delivery systems struggle to handle extreme flow rates and high temperatures in semiconductor processing and petrochemical applications, particularly in maintaining mechanical integrity and sealing efficiency while accommodating diverse fluid handling components.
Innovation Solution
The development of flow substrates with adjustable conduit sizes and secure fastening mechanisms, utilizing swaging and welding techniques for stainless steel or polymer materials, along with integrated or individual caps for sealing, to ensure robust mechanical alignment and sealing across various fluid handling components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If gaskets are used to seal fluid components to flow substrates, then ease of assembly is improved, but reliability deteriorates under extreme temperatures and high flow rates
Solution Approach 1:
The patent replaces the mechanical gasket-based sealing system with a welding-based sealing system. The weld cap and plug weld techniques create permanent metallurgical bonds between fluid components and flow substrates, eliminating reliance on deformable gaskets that fail under extreme temperatures and high flow rates. This substitution maintains ease of assembly through standardized welding procedures while dramatically improving sealing reliability in extreme conditions.
2Device complexity
If standardized interfaces are used for fluid handling components, then device complexity is reduced, but adaptability deteriorates for extreme flow rates and high temperatures
Solution Approach 1:
The patent changes the joining parameter from mechanical (gasket compression) to thermal (welding). This parameter change enables the same standardized interface geometry to be adapted for extreme conditions by using welding techniques that create permanent, high-integrity bonds capable of withstanding extreme temperatures and high flow rates, while maintaining the benefits of standardized interfaces.
3Reliability
If metallic seals are used for high purity fluid delivery, then reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The welding process creates self-sealing joints where the molten metal fills gaps and defects automatically during welding, eliminating the need for complex precision machining or assembly procedures. The weld cap design with its specific geometry allows the welding process itself to create the seal, reducing manufacturing complexity while maintaining high purity fluid delivery through reliable metallic seals.
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 enables efficient fluid delivery at extreme flow rates and temperatures, maintaining mechanical integrity and sealing efficiency, while allowing for versatile integration with symmetric or asymmetric port placements, and facilitating easy maintenance and serviceability.
Implementation Method 1
the substrate body lip is configured to be swaged by a press
Implementation Method 2
The weld cap and plug welds for fluid delivery systems
Data Source
Figure 1A~1B
Figure 1C~1F
Figure 1G~1I
AI summary
A flow substrate comprising a substrate body formed from a solid block of a first material, the substrate body defining an opening in a first surface of the substrate body; a substrate body lip that extends from the first surface of the substrate body about a circumference of the opening in the first surface of the substrate body; a tube stub disposed in the opening, wherein the substrate body lip is configured to be swaged by a press; and a tube stub disposed in the opening of the substrate body, the tube stub configured to be coupled with the substrate body upon swaging of the substrate body lip with the press.