Anchoring Washer Cap Securement for Fastener Electrical Isolation
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Solution Overview
Problem
Existing electrical insulation cap systems 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.
Innovation Solution
A cap system with a securement mechanism featuring threads and tabs around a washer, allowing for easy engagement and secure positioning of a cap member over the fastener assembly, which also includes a nonconductive material for electrical isolation and a design that prevents sealant expulsion and simplifies the sealing process.
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 sealant must be smoothed out which is tedious and time consuming
Solution Approach 1:
The patent extracts the harmful excess sealant from the cap during installation through dedicated expulsion channels, eliminating the need for post-installation smoothing operations while maintaining adequate sealant presence for electrical insulation and sealing functions
Solution Approach 2:
The patent introduces intermediary expulsion channels as mediators between the sealant reservoir and external environment, allowing controlled removal of excess sealant during installation without compromising the sealing function, thus resolving the contradiction between reliable sealing and installation efficiency
2Manufacturing precision
If the cap is held in place during sealant curing to prevent slumping or lifting, then proper positioning is maintained, but the process requires extended time and rework for high quality standards
Solution Approach 1:
The patent incorporates preliminary positioning features directly into the cap structure that automatically maintain correct positioning during the sealant curing process, eliminating the need for extended manual holding and reducing both time and labor requirements while ensuring manufacturing precision
3Reliability
If a securement mechanism is added to the cap system, then reliable securement is achieved, but device complexity increases
Solution Approach 1:
The patent integrates multiple functions into the cap structure including securement features, sealant expulsion channels, and positioning elements, allowing a single component to perform multiple roles thereby achieving reliable securement without proportionally increasing overall device complexity
Data Source
AI summary
A cap system for enclosing a metallic fastener assembly extending through a structure, which includes a first securement mechanism positioned about a periphery of a washer of the metallic fastener assembly wherein the first securement mechanism includes a first tab member extending in a direction transverse to a plane of a surface of the washer and a second tab member extending in a direction transverse to the plane of the surface of the washer spaced apart from the first tab member about the periphery of the washer. Cap system further includes a cap member which includes a sidewall having an inner surface which defines a cavity dimensioned to receive the washer and defines a second securement mechanism complementary configured to engage the first securement mechanism; and an end of the sidewall of the cap member defines an opening which provides the washer to have access into the cavity.