Fitted Cap for Uniform Sealant Shroud on Fasteners
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Solution Overview
Problem
Manual brush application of sealant to fasteners is laborious, time-consuming, and lacks quality control, leading to inefficient and inconsistent results in aircraft assembly, where irregular fastener surfaces complicate the application process.
Innovation Solution
A system comprising a fitted cap and cap-manipulation tool that uses a precursor cap and polymer sheet to form a shaped sealant shroud around fasteners, ensuring uniformity and continuity of sealant application through vacuum-forming and rotational distribution of sealant, preventing air bubbles and imperfections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual brush application is used, then the sealant can be applied to irregular fastener surfaces, but the application process becomes laborious and time-consuming
Solution Approach 1:
The fitted cap is designed to be self-aligning on the fastener, automatically positioning itself correctly without requiring manual alignment by the operator. The cap's geometry complements the fastener shape, enabling it to self-position and self-adjust during application, thereby reducing manual effort while maintaining productivity
Solution Approach 2:
The sealant is pre-loaded into the fitted cap before application. The cap comes prepared with the sealant reservoir and dispensing mechanism already in place, eliminating the need for manual brush loading and preparation steps during the actual application process
2Reliability
If manual brush sealing is used, then the operator can control sealant application, but quality control becomes difficult and rework is required
Solution Approach 1:
The fitted cap incorporates a precisely engineered nozzle or dispensing opening at the correct location and orientation relative to the fastener surface. This localized feature ensures that sealant is deposited only where needed, with controlled flow characteristics, achieving consistent quality without requiring complex external control mechanisms
Solution Approach 2:
The manual brush sealing process is replaced with a mechanical dispensing system integrated into the fitted cap. The cap uses mechanical features such as gravity-fed flow, capillary action, or pressure-controlled dispensing to automate sealant application, eliminating variability associated with manual brush technique while maintaining simple overall device design
3Productivity
If non-brush applicators are used, then sealant application can be automated, but method consistency and traceability deteriorate
Solution Approach 1:
The fitted cap replicates the essential functional features of manual brush application in a standardized mechanical form. By copying the sealant delivery function through a fixed geometric nozzle design rather than a variable brush, the system achieves automation while maintaining consistency through geometric replication rather than human skill replication
Solution Approach 2:
The invention changes the key parameter from operator skill level to fixed geometric dimensions. The nozzle opening size, shape, and position are defined by precise manufacturing tolerances, transforming the application process from one dependent on human capability to one governed by measurable physical parameters that ensure consistency and traceability
4Device complexity
If brush application is used, then the process is simple, but uniformity and continuity of sealant coverage are poor
Solution Approach 1:
The fitted cap is designed with a curved or contoured exterior surface that matches the cylindrical or irregular shape of the fastener. This geometric complementarity ensures continuous contact between the cap and fastener surface, enabling uniform sealant distribution around the entire fastener perimeter while maintaining a relatively simple cap structure
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
The system significantly reduces application time and improves quality by providing a uniform sealant distribution around fasteners, enhancing efficiency and consistency in aircraft assembly.
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
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) positionable such that a uniform gap (302) is formed between a wall (305) of the cap and the portion (106) of the fastener (100). The fitted cap (300) further comprises an inlet opening (306) and a vent (309) each configured to be communicatively coupled with the uniform gap (302). The system (501) also comprises a cap-manipulation tool (500) comprising a shaft (510) comprising a through, circumferentially closed, channel (516), configured to receive sealant (592) and to communicate the sealant (592) therethrough. The channel (516) is capable of communicating the sealant (592) through the inlet opening (306) of the fitted cap (300) into the uniform gap (302), and the vent (309) is oriented to purge gas from the uniform gap (302). The fitted cap (300) is rotatable together with the shaft (510) to distribute the sealant (592) in the uniform gap (302) to form the shaped sealant shroud (590).