One-Sided Aperture Plug Assembly with Rotation-Locking Collar
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Solution Overview
Problem
Existing plug assemblies for apertures in bodies, such as turbine engine cases, often suffer from leakage issues and require access to both sides for secure installation, which is not always feasible.
Innovation Solution
A plug assembly comprising a collar, fastener, and retainer that can be assembled without access to the second side of the body, utilizing a biasing member and indicators to ensure proper alignment and sealing, with a head that changes orientation to fit within or overlap the aperture's cross-sectional geometry, limiting rotation and providing a seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a traditional plug assembly is used to seal an aperture, then sealing capability is achieved, but access to both sides of the body is required for installation
Solution Approach 1:
The plug assembly is divided into separate components: a collar that fits into the aperture, a fastener that threads through the collar, and a retainer that secures the assembly. This segmentation allows the components to be installed sequentially from one side, eliminating the need for access to both sides while maintaining structural integrity and sealing capability.
Solution Approach 2:
Instead of requiring the plug to be secured from both sides as in traditional designs, the invention inverts the approach by designing a one-sided installation system where the fastener and retainer work together to secure the plug from a single access point, fundamentally changing the installation methodology.
2Reliability
If a simple plug design is used, then device complexity is reduced, but leakage resistance deteriorates
Solution Approach 1:
The collar is designed with a sealing surface that locally contacts the aperture opening, providing a dedicated sealing zone. This localized sealing structure ensures reliable leakage prevention without requiring complex overall design, as the sealing function is concentrated in the specific area where it is most critical.
Solution Approach 2:
The collar is pre-configured with the sealing surface geometry and dimensions to match the aperture, so that when installed, the sealing action is already prepared and immediately effective. This preliminary configuration ensures reliable sealing without requiring additional sealing steps or complex adjustment mechanisms.
3Ease of operation
If a plug assembly allowing one-sided installation is used, then installation accessibility is improved, but rotation control between components deteriorates
Solution Approach 1:
The fastener head and retainer are designed with asymmetric engagement features, such as non-circular profiles or keyed interfaces, that prevent rotational misalignment. This asymmetric design ensures that the components can only be assembled in the correct orientation, providing inherent rotation control while maintaining one-sided installation capability.
Solution Approach 2:
The fastener is nested within the collar structure, with the fastener shaft passing through the collar and the head engaging with the retainer on the opposite side. This nested arrangement provides mechanical interlocking that limits rotation between components, ensuring stable assembly while allowing installation from one side.
Data Source
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AI summary
An apparatus includes a body 24, a collar 26, a fastener 28 and a retainer 30. The body 24 extends between first 46 and second 68 sides. The collar 26 sealingly engages the first side 46 and extends into an aperture 22 in the body 24. The fastener 28 engages the second side 68 and extends through the collar 26 to a distal end 74. The retainer 30 is mated with the fastener 28 at the distal end 74. The collar 26 and the fastener 28 cooperate to limit rotation therebetween.