Fastener Cap Engagement and Sealant Injection for EMI Sealing
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Solution Overview
Problem
Existing methodologies for covering protruding fasteners with insulating caps are labor-intensive and time-consuming, particularly when requiring internal and external application of sealant to inhibit electromagnetic energy and hot particle discharge.
Innovation Solution
A system and method involving a cap with an interior, base, pawls, and a tooth configured to positively engage the fastener, along with a nut or collar, which includes a threaded receptacle and a sealant injection mechanism to facilitate efficient and automated cap installation over fasteners, ensuring secure engagement and sealant application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing methodologies are used to cover protruding fasteners with insulating caps requiring internal and external application of sealant, then electromagnetic energy and hot particles are inhibited from being discharged, but the process becomes labor-intensive and time-consuming
Solution Approach 1:
The cap system performs sealing functions automatically through its integrated design features. The sealant injection mechanism dispenses sealant internally without requiring external application, and the pawl-tooth engagement system automatically secures the cap to the fastener, eliminating the need for manual sealant application and reducing labor-intensive steps
Solution Approach 2:
Multiple functions are combined into a single integrated cap system: the sealant injection mechanism is incorporated within the cap structure, the pawl-tooth engagement system is built into the cap and fastener interface, and the insulating cap itself provides both electromagnetic inhibition and structural coverage. This merging of functions reduces the number of separate operations required
2Productivity
If automated installation is implemented for cap covering fasteners, then installation time and labor are reduced, but secure engagement and proper sealing must be maintained
Solution Approach 1:
The manual mechanical process of applying sealant and securing caps is replaced with an automated injection mechanism that dispenses sealant through a nozzle into the cap's interior. The pawl-tooth engagement system provides automatic mechanical securing that ensures reliable attachment without requiring manual intervention, while maintaining secure engagement through the interlocking geometry of the pawls and tooth
Solution Approach 2:
The sealant acts as an intermediary substance that is automatically injected into the cap interior to create the sealing interface between the cap and fastener. This intermediary material ensures proper sealing is achieved through the automated process, maintaining reliability while enabling automation
Data Source
AI summary
A method of covering a portion of a fastener, protruding from a surface, that comprises providing a cap comprising a wall, a base, an interior, at least partially delimited by the wall and the base, and pawls, located in the interior of the cap. The method further comprises coupling a tooth to the fastener, covering the portion of the fastener with the cap, and positively engaging the pawls with the tooth, such that the pawls are loaded in tension against the tooth.