Anchoring Nut Cap Securement for Fast Electrical Isolation
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Solution Overview
Problem
Existing electrical insulation cap assemblies for metallic fasteners are time-consuming to install and require tedious smoothing of excess sealant, and lack a reliable securement mechanism, especially in critical areas like aircraft fuel tanks and sensitive electronic equipment, where electromagnetic effects and lightning strikes are a concern.
Innovation Solution
A cap system with a nonconductive cap member featuring various securement mechanisms such as interrupted threads, continuous threads, grooves, or annular ledges that securely engage with the nut member of the metallic fastener assembly, allowing for easy installation and reliable sealing without excess sealant expulsion, using a nonconductive material and sealant for enhanced electrical isolation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional sealant caps are filled with liquid sealant material, then electrical insulation and sealing are achieved, but excess sealant must be smoothed out which is tedious and time consuming
Solution Approach 1:
The cap is pre-filled with sealant material during manufacturing, and includes a breakable seal that controls sealant release. This preliminary preparation eliminates the need for on-site smoothing operations, reducing installation time while maintaining sealing quality.
Solution Approach 2:
The sealant material transitions from liquid to cured state through controlled curing. The breakable seal mechanism allows precise control of when and how the sealant is released, changing the parameter of sealant flow control from manual smoothing to mechanical release.
2Manufacturing precision
If the cap is held in place during curing to prevent slumping or lifting, then proper positioning is maintained, but the process requires additional time and attention
Solution Approach 1:
The cap includes pre-formed engagement features such as flanges, ribs, or threaded portions that automatically engage with corresponding features on the fastener or structure. This preliminary design ensures proper positioning is maintained during curing without requiring continuous monitoring or adjustment.
Solution Approach 2:
The cap's own structural features provide the securing mechanism during curing. The engagement features are integral to the cap design, allowing it to self-secure in the correct position without external intervention or additional fastening operations.
Data Source
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AI summary
A cap system (26C) for enclosing a metallic fastener assembly (11) extending through a structure (14) includes a first securement mechanism (34C) positioned about a periphery of a nut member (22) of the metallic fastener assembly, wherein the first securement mechanism comprises a plurality of grooves (37C) positioned about the periphery of the nut member, and a cap member (28C), wherein the plurality of grooves are spaced apart about the periphery of the nut member, the nut member includes a plurality of ridge members (46C) which extend in a radial direction away from the nut member and define the plurality of grooves, and adjacent ridge members are spaced apart about the nut member. The cap member includes a sidewall (29C) having an inner surface which defines a cavity dimensioned to receive the nut member and defines a second securement mechanism complementary configured to engage the first securement mechanism positioned about the periphery of the nut member and an end of the sidewall of the cap member defines an opening which provides the nut member to have access into the cavity.