Weldable Thermoplastic Seal Composition for Large-Diameter Rings
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Solution Overview
Problem
PTFE filled thermoplastic polymers, such as PTFE filled PEEK, exhibit reduced elongation-at-break when welded, making them less suitable for forming large diameter seals using heat welding processes, which is a challenge in the industry that demands improved seal properties and performance.
Innovation Solution
A seal comprising a body made of a blend of thermoplastic material and fluoropolymer filler, where the fluoropolymer particles are uniformly dispersed in the thermoplastic matrix with controlled size and distribution, enhancing the elongation-at-break and coefficient of friction, and suitable for heat welding processes, particularly for large diameter seals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If PTFE filled thermoplastic polymers are used in heat welding processes, then wear characteristics and low friction are improved, but elongation-at-break is reduced
Solution Approach 1:
The patent changes the particle size parameter of the PTFE filler from conventional larger sizes to specifically 1-10 microns, and controls the filler content within 5-50 wt%. This parameter optimization resolves the contradiction by achieving both good wear characteristics and maintained elongation-at-break properties in the welded seal
Solution Approach 2:
The patent creates a composite material system combining thermoplastic polymer matrix with controlled PTFE filler particles. The composite structure allows the thermoplastic to provide ductility and weldability while the PTFE particles provide wear resistance and low friction, resolving the property trade-off
2Reliability
If PTFE filled thermoplastic polymers are used for large diameter seals, then seal performance is improved, but manufacturing difficulty increases due to heat welding process limitations
Solution Approach 1:
The patent optimizes PTFE particle size to 1-10 microns and controls filler content at 5-50 wt%, which improves the processability and weldability of the material. This allows large diameter seals to be manufactured through heat welding processes that were previously difficult or impossible, while maintaining seal performance
Solution Approach 2:
The patent ensures uniform local distribution of PTFE particles throughout the thermoplastic matrix, creating consistent local properties that enable reliable welding at all locations in large diameter seals, making manufacturing feasible
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 achieves improved elongation-at-break and reduced coefficient of friction, making the seals more suitable for large diameter applications and enhancing their performance and manufacturing feasibility through heat welding.
Implementation Method 1
PTFE filled thermoplastic polymers are desirable for their wear characteristics and low friction
Implementation Method 2
heat welding processes are used in forming large diameter seals
Implementation Method 3
the welded portion of seals formed with PTFE filled PEEK
Data Source
AI summary
A seal can include a body including a thermoplastic material and a filler material including a fluoropolymer. The fluoropolymer can include a modified fluoropolymer. The body can include an elongation-at-break of at least 3%. In an embodiment, the seal can include a seal ring, wherein the body of the seal ring can include a weld.