Fitted Cap Sealant Shroud for Uniform Fastener Sealing
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Solution Overview
Problem
Manual brush application of sealant to fasteners is laborious, time-consuming, and prone to quality control issues, with existing sealant applicators requiring skilled operators and having inconsistent methods of use and traceability.
Innovation Solution
A system comprising a support plate, fastener template, precursor cap, and cap-manipulation tool, where a polymer sheet is vacuum-formed over the precursor cap to create a fitted cap that applies a shaped sealant shroud to fasteners, allowing for uniform sealant application and easy rotation to distribute sealant evenly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual brush application is used, then sealant can be applied to fasteners, but the process is laborious, time-consuming, and has poor quality control
Solution Approach 1:
The fitted cap is designed to self-align with the fastener through its geometric complementarity to the fastener template, creating a uniform gap automatically without requiring skilled operator intervention. The cap-manipulation tool rotates the fitted cap to self-distribute sealant evenly around the fastener, eliminating the need for manual brush application while ensuring consistent quality.
Solution Approach 2:
The fitted cap acts as an intermediary between the sealant and the fastener. It receives sealant through the inlet opening, maintains a uniform gap around the fastener, and distributes the sealant evenly as it rotates, thereby mediating the sealant application process to achieve consistent quality and high productivity.
2Ease of operation
If existing sealant applicators are used, then sealant application is possible, but skilled operators are required and methods of use are inconsistent
Solution Approach 1:
The fitted cap self-aligns with the fastener through its geometric design that is complementary to the fastener template, automatically creating a uniform gap without requiring operator skill. The cap-manipulation tool simply rotates the cap, and the system self-distributes the sealant evenly, eliminating the need for skilled operators and ensuring consistent results.
Solution Approach 2:
The sealant application process is segmented into distinct functional components: the fitted cap that maintains uniform gap, the inlet opening that receives sealant, and the rotation mechanism that distributes sealant. This segmentation allows each component to perform its function independently and consistently, improving ease of operation and reliability.
3Productivity
If manual brush sealing is used, then sealant can be applied, but rework is often required due to quality issues
Solution Approach 1:
The fitted cap automatically maintains a uniform gap around the fastener through its geometric design, and the rotation mechanism self-distributes sealant evenly, eliminating the quality variations that cause rework. This self-service approach ensures high productivity without the need for expensive rework.
Solution Approach 2:
The system changes the physical state and distribution parameters of the sealant by controlling the uniform gap width and rotation speed, ensuring consistent sealant thickness and coverage. This parameter control prevents quality defects that would require rework, while maintaining high application speed.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Facilitates efficient and uniform application of sealant to fasteners, reducing labor and improving quality by enabling a single cap-manipulation tool to work with various sizes and shapes of fitted caps, ensuring consistent sealant distribution and preventing air bubbles or imperfections.
Implementation Method 1
first means for heating a first polymer sheet to a specified temperature
Implementation Method 2
second means for applying suction to the first polymer sheet, positioned a predetermined distance from the first side of the support plate and heated to the specified temperature by the first means, through the first plurality of through-openings from the second side of the support plate to vacuum-form the first polymer sheet over the precursor cap
Data Source
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AI summary
A system (501) for applying a shaped sealant shroud (590) to a portion (106) of a fastener (100) comprises a fitted cap (300), comprising a wall (305) and positionable over the portion (106) of the fastener (100) such that a uniform gap (302) is formed between the wall (305) and the portion (106) of the fastener (100). The fitted cap (300) further comprises an inlet opening (306) and a vent (309), communicatively coupled with the uniform gap (302). The system (501) also comprises-a cap-manipulation tool (500), comprising a shaft (510) with a longitudinal central axis (518) and a through, circumferentially closed, channel (516), configured to receive sealant (592). The vent (309) purges gas from the uniform gap (302) as the sealant (592) is communicated through the through, circumferentially closed, channel (516) into the uniform gap (302). The fitted cap (300) is rotatable to distribute the sealant (592) in the uniform gap (302) to form the shaped sealant shroud (590) around the portion (106) of the fastener (100).