Bolt Head 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 they are prone to slumping or lifting during the curing process.
Innovation Solution
A cap system with a nonconductive cap member featuring a securement mechanism around the bolt head, including interrupted or continuous threads and annular ledges/grooves, which securely engages the cap to the bolt head and structure, ensuring reliable positioning and sealing without expelling excess sealant, thus reducing installation time and enhancing securement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional sealant caps are used to electrically insulate metallic fasteners, then electrical isolation is achieved, but installation time increases and excess sealant smoothing becomes tedious
Solution Approach 1:
The patent extracts the problematic excess sealant smoothing step from the installation process by designing a cap system that contains the sealant within the cap structure itself, eliminating the need for external smoothing operations and reducing installation time while maintaining electrical isolation
Solution Approach 2:
The cap system is segmented into distinct functional components: the cap body containing the sealant, the securement mechanism with threads and ledges, and the integration with the bolt head. This segmentation allows each component to perform its specific function efficiently without interfering with other installation steps
2Ease of operation
If traditional cap securement methods are used, then cap coverage is achieved, but the cap is prone to slumping or lifting during curing
Solution Approach 1:
The securement mechanism with threads and annular ledges is pre-integrated into the cap structure before installation. This preliminary configuration ensures that the cap is mechanically locked to the bolt head from the outset, preventing slumping or lifting during the sealant curing process without requiring additional securing steps
Solution Approach 2:
The cap system combines different material properties: the cap body material providing electrical insulation, the sealant material providing adhesive bonding, and the metallic threads providing mechanical securement. This composite approach ensures both ease of positioning and reliable securement simultaneously
3Reliability
If cap system with securement mechanism is implemented, then securement reliability improves, but device complexity increases
Solution Approach 1:
The patent merges multiple functions into the cap structure: the cap body provides electrical insulation, the integrated threads provide securement, and the annular ledges provide positioning and support. By combining these functions into a single integrated component rather than separate parts, the system achieves high securement reliability without proportionally increasing overall device complexity
Data Source
AI summary
A cap system for enclosing a metallic bolt fastener extending through a structure which includes a first securement mechanism positioned about a periphery of a bolt head of the metallic bolt fastener. The cap system further includes a cap member which includes a sidewall having an inner surface which defines a cavity dimensioned to receive the bolt head and defines a second securement mechanism complementary configured to engage the first securement mechanism positioned about the periphery of the bolt head. The cap system further includes an end of the sidewall of the cap member which defines an opening which provides the bolt head access into the cavity.