Z-Layer Threaded Connectors for Leak-Resistant Sealing
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Solution Overview
Problem
Standard threaded connections in fluid transport applications often leak due to insufficient surface contact, necessitating secondary sealing structures that increase costs and reduce reliability, while traditional machining processes struggle to efficiently produce complex geometries required for advanced threaded connectors like Van Cor Threads.
Innovation Solution
The implementation of Z layer engineering in 3D printing, which modifies the coordinates of existing components to create Z ridges and seats that enhance surface contact and sealing capabilities without the need for secondary sealing structures, by extending or retracting layers to form plugs, seats, and channels that align mechanical stresses and improve sealing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If standard threaded connections are used, then manufacturing is simple, but surface contact is insufficient (30-35%) causing leaks
Solution Approach 1:
The thread structure is segmented into multiple functional zones including tapered sections, cylindrical sections, and sealing sections with specific surface contact characteristics. This segmentation allows each zone to perform its specific function while achieving overall sealing capability without requiring secondary sealing structures
Solution Approach 2:
The invention transitions from conventional 2D thread profiles to 3D complex geometries with varying radii, tapered sections, and cylindrical sections. This dimensional enhancement creates multiple surface contact points and areas, increasing overall surface contact from 30-35% to near-total contact and enabling reliable sealing
2Ease of manufacture
If traditional machining processes are used, then manufacturing is conventional, but complex geometries cannot be produced efficiently
Solution Approach 1:
The invention replaces traditional mechanical machining processes with additive manufacturing (3D printing) technology. This substitution enables the efficient production of complex thread geometries with high precision tolerances that would be difficult or impossible to achieve through conventional machining methods
Solution Approach 2:
The invention utilizes adjustable printing parameters in additive manufacturing including layer thickness, infill density, and material composition to achieve the required geometric tolerances and surface finishes. These parameter changes allow optimization of both manufacturing efficiency and precision for complex thread geometries
3Reliability
If secondary sealing structures are used, then sealing is achieved, but cost increases and reliability decreases
Solution Approach 1:
The invention merges the sealing function directly into the thread structure itself by designing threads with near-total surface contact and appropriate material elasticity. This integration eliminates the need for separate secondary sealing structures such as gaskets, O-rings, or thread compounds, reducing component count while maintaining or improving seal integrity
Solution Approach 2:
The thread structure is designed to be self-sealing through its geometry and material properties. The near-total surface contact and material elasticity enable the threads to create their own seal without requiring additional sealing materials or structures, making the system self-sufficient
Data Source
AI summary
A threaded connector system including a male threaded connector and a female part, where at least one of the outer surface of the male threaded connector and the inner surface of the female part includes at least one Z layer structure, including a Z seat, Z ridge, Z rib, Z tooth, Z snap lock, Z stack and Z channel.