UV-Curable Seal Member Forming System for Heat-Sensitive Substrates
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Solution Overview
Problem
Current methods for forming seal members, such as O-rings and foam tapes, are labor-intensive and lack precision, while existing automated methods like FIPG and LIM forming face challenges in controlling bead height and shape, and require expensive equipment, especially when working with heat-sensitive parts.
Innovation Solution
A system and method utilizing a mold with ultraviolet transmissible material and an ultraviolet irradiation device to cure the seal material, allowing for precise formation of seal members on substrates with automated processes, enabling high dimensional accuracy and flexibility in shape without the need for heat-sensitive equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If FIPG application is used for automated seal member formation, then productivity is improved, but manufacturing precision deteriorates due to difficulty in controlling bead heights and shapes
Solution Approach 1:
The patent replaces the mechanical dispensing system of FIPG with an injection molding system. The applicator injects curable material through a channel into a mold cavity, where the mold's geometric structure precisely defines the seal member's cross-sectional shape. This mechanical substitution eliminates the bead control issues of FIPG while maintaining automation.
Solution Approach 2:
The patent changes the curing method from thermal curing (heating) to ultraviolet light curing. This parameter change allows the use of UV-transmissible mold materials that enable precise shape definition through the mold geometry, while avoiding heat-related dimensional instability in the sealing material.
2Manufacturing precision
If LIM forming is used for seal member formation, then manufacturing precision is improved, but device complexity increases due to expensive special forming machines
Solution Approach 1:
The patent creates a multi-functional apparatus that combines the applicator (for material injection) and the mold (with integrated UV transmissible portions and cavities) into a single system. This universal device can form seal members with precise dimensions without requiring separate expensive LIM forming equipment, achieving precision with simpler integrated hardware.
3Reliability
If heating is used to cure seal material in LIM or FIPG methods, then reliability of sealing is improved, but adaptability deteriorates for heat-sensitive parts
Solution Approach 1:
The patent changes the curing parameter from thermal energy to ultraviolet light energy. The seal material is formulated to cure via UV irradiation rather than heating, enabling the system to process heat-sensitive parts while maintaining reliable curing. This parameter change expands adaptability without compromising sealing reliability.
Solution Approach 2:
The patent substitutes thermal curing mechanisms with ultraviolet light curing mechanisms. By replacing heat-based curing with photopolymerization, the system achieves reliable material curing without subjecting heat-sensitive parts to damaging temperatures, thus expanding versatility.
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 the automated, high-accuracy formation of seal members with desired cross-sectional shapes on substrates, even for heat-sensitive parts, reducing labor costs and equipment expenses while improving dimensional precision.
Implementation Method 1
an ultraviolet irradiation device configured to irradiate the mold with ultraviolet light to cure the material when the material is provided to the second cavity
Data Source
AI summary
A system and method for forming a seal member onto a substrate from a material is disclosed. The system includes a mold comprising an ultraviolet transmissible material, the mold having a first portion and a second portion operatively coupled to the first portion, the first portion having a first cavity, a second cavity, and a channel extending from an outer surface of the mold to the second cavity. The first cavity has a first shape that is complementary to a first side of the substrate and the second cavity has a second shape that is complementary to the seal member. The system also includes an applicator in fluid communication with the channel, where the applicator is configured to provide the material to the second cavity through the channel, and an ultraviolet irradiation device configured to irradiate the mold with ultraviolet light to cure the material when the material is provided to the second cavity, such that the seal member is formed on the substrate.