Double-Wall Fastener Cap to Contain Uncured Sealant
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical insulation containment apparatuses for metallic fasteners are inefficient in preventing uncured sealant from escaping during installation, leading to labor-intensive smoothing and visual inspection processes, and potential adhesion issues.
Innovation Solution
A containment apparatus with a cap member design that includes a first and second wall member configuration, where the second wall member surrounds the first to form a second cavity, preventing uncured sealant from exiting during installation and providing additional securement when cured, thereby reducing labor and costs associated with smoothing and adhesion testing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If uncured sealant is used within the cap member, then the sealant can be applied and positioned, but the uncured sealant is displaced and squeezed out during installation requiring smoothing
Solution Approach 1:
The cap member is divided into two distinct cavities: a first cavity for containing the uncured sealant and a second cavity formed by a second wall member that provides additional containment. This segmentation prevents the sealant from being squeezed out during installation while maintaining ease of application.
Solution Approach 2:
The second wall member is pre-installed on the cap member before the uncured sealant is applied to the fastener. This preliminary action creates a pre-formed containment structure that prevents sealant displacement during the subsequent installation process, eliminating the need for post-application smoothing.
2Reliability
If uncured sealant is contained within the cap member, then electrical insulation is provided, but the sealant may escape during installation requiring additional containment
Solution Approach 1:
The second wall member is nested over the first wall member of the cap member, creating a double-walled containment structure. This nested configuration provides enhanced sealant containment and electrical insulation while maintaining a compact design that does not significantly increase overall device complexity.
3Productivity
If the cap member is installed with uncured sealant, then the fastener is enclosed, but labor and time are required for smoothing and inspection
Solution Approach 1:
The second wall member is pre-installed on the cap member before the uncured sealant is applied to the fastener. This preliminary action creates a pre-formed containment structure that prevents sealant displacement during the subsequent installation process, eliminating the need for post-application smoothing and inspection.
Solution Approach 2:
The double-cavity containment structure is designed to automatically contain and secure the uncured sealant during installation without requiring external intervention for smoothing or additional containment measures. The structure serves itself by providing inherent sealant retention capabilities.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A containment apparatus for enclosing a metallic fastener extending through a structure includes a cap member. The cap member includes a first wall member which defines a first cavity and a first end. The first end defines a first opening providing access into the first cavity for at least a portion of the metallic fastener. The cap member further includes a second wall member secured to and extends from an exterior surface of the first wall member. The second wall member extends spaced apart from and along the first wall member to a first end. The second wall member surrounds the first wall member such that first wall member and second wall member form a second cavity positioned between the first wall member and the second wall member. The first end of the first wall member and the first end of the second wall member are coplanar with one another.