Weld Cap and Swaged Plug Sealing for High-Temperature Flow Substrates
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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 industries, particularly in maintaining fluid purity and sealing integrity under varying conditions.
Innovation Solution
The development of flow substrates with adjustable conduit cross-sectional areas and secure fastening mechanisms, utilizing swaged joints and swaged plugs to ensure mechanical alignment and sealing, allowing for asymmetric or symmetric port placements and compatibility with various fluid handling components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If deformable gaskets are used to seal fluid components to flow substrates, then sealing is achieved, but reliability deteriorates under extreme flow rates and high temperatures
Solution Approach 1:
The patent removes the deformable gasket from the sealing system and replaces it with a rigid seal configuration. The fluid component is directly sealed to the flow substrate using rigid sealing surfaces and fastening mechanisms, eliminating the gasket that fails under extreme conditions. This extraction of the problematic gasket element resolves the reliability issue while maintaining sealing functionality.
Solution Approach 2:
The patent replaces the mechanical gasket-based sealing system with a rigid mechanical fastening and sealing system. Instead of relying on deformable gasket material to create seals, the system uses rigid sealing surfaces配合 fastening mechanisms (such as cap screws, clamp mechanisms, or interference fits) to maintain sealing integrity under extreme flow rates and high temperatures.
2Ease of manufacture
If standardized joining methods with gaskets are used, then ease of manufacture is improved, but adaptability deteriorates for extreme flow rate and high temperature applications
Solution Approach 1:
The patent designs fluid components with standardized mounting interfaces and rigid sealing configurations that can be universally applied across different flow substrate types. The rigid seal and fastening mechanism system serves multiple functions: providing sealing, mechanical attachment, and adaptability to various extreme condition requirements, replacing the single-function gasket system.
3Reliability
If rigid sealing without gaskets is used, then reliability under extreme conditions is improved, but ease of manufacture deteriorates
Solution Approach 1:
The patent incorporates pre-formed rigid sealing surfaces and integrated fastening features directly into the fluid component and flow substrate design. The rigid sealing surfaces are precision-machined or formed as integral features during manufacturing, and fastening mechanisms are pre-configured, eliminating the need for complex assembly procedures while ensuring reliable sealing under extreme conditions.
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 reliable fluid delivery at extreme flow rates and temperatures, maintaining purity and sealing integrity while facilitating easy maintenance and adaptability to different industrial applications.
Implementation Method 1
at least one cap formed from a second material, the at least one cap having a first cap surface that is constructed to seal at least one fluid pathway of the plurality of fluid pathways
Implementation Method 2
securing the weld cap to the substrate body through a swaged joint
Implementation Method 3
securing the plug to the substrate body through a swaged joint formed as a result of said pressing
Data Source
AI summary
A flow substrate comprising a substrate body formed from a solid block of a first material, the substrate body having a first surface and a second surface opposing the first surface, a plurality of pairs of component conduit ports defined in the first surface of the substrate body, a plurality of fluid pathways extending between each respective pair of component conduit ports and in fluid communication with each component conduit port of the respective pair of component conduit ports, each respective fluid pathway being formed in the second surface of the substrate body; and at least one cap formed from a second material, the at least one cap having a first cap surface that is constructed to seal at least one fluid pathway, and a second cap surface opposing the first surface, wherein the substrate body includes an opening configured to couple with the at least one cap.