Inflatable Bore Coating Applicator for Uniform Conductive Contact

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Solution Overview

Problem

Current techniques for applying conductive coatings to fastener holes in composite manufacturing are inefficient, providing limited conductivity and are time-consuming, with issues of angular contact and uneven pressure between the bolt and the hole.

Innovation Solution

An applicator tool with a tubular body and inflatable bladder is used, where the expansion portion is inserted into the bore, and pressurized fluid is applied to expand the bladder, allowing the coating material to be evenly applied to the bore surface through rotation of the tool.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a coated bolt is inserted and spun with a drill, then conductivity is applied to the fastener hole, but the contact is angular and pressure is uneven

Engineering Contradiction:

ImproveconductivityVSAvoidcontact uniformity

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent introduces a specialized applicator tool as an intermediary device between the coating material and the fastener hole. This tool includes a coated insert that rotates within the hole, providing controlled and uniform contact with the bore surface. The intermediary tool ensures even pressure distribution and consistent conductivity application, resolving the angular contact and uneven pressure issues of direct bolt spinning methods.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent employs dynamic rotation of the applicator tool insert within the fastener hole during the coating process. The insert rotates to distribute the conductive material uniformly around the entire circumference of the hole, transforming the static angular contact of traditional methods into dynamic, controlled, and evenly distributed contact. This rotational motion ensures consistent pressure and conductivity application throughout the bore surface.

Inventive Principle:

Principle #15Dynamics

2Reliability

If current coating techniques are used, then conductivity is applied to fastener holes, but the process is time-consuming

Engineering Contradiction:

ImproveconductivityVSAvoidcoating process efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent applies preliminary action by pre-coating the insert of the applicator tool with conductive material before insertion into the fastener hole. This pre-preparation allows for rapid application during the actual coating process, eliminating time-consuming steps of material application during the operation itself. The pre-coated insert is ready to transfer material uniformly and efficiently upon rotation within the hole.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces the complex mechanical system of drilled and spun coated bolts with a simpler applicator tool system. The new system uses a pre-coated insert that rotates within the hole, substituting the need for drilling operations and complex bolt spinning mechanisms. This mechanical substitution significantly reduces process time while maintaining or improving conductivity application quality.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If a coated bolt is spun with a drill, then the bolt contacts the fastener hole, but replaceable parts are not used

Engineering Contradiction:

ImproveconductivityVSAvoidpart replaceability

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent segments the applicator tool into replaceable components, including the insert that contacts the fastener hole and the main tool body. The insert can be easily removed and replaced, allowing for maintenance, wear replacement, and adaptability to different hole sizes. This segmentation provides replaceable parts functionality that was missing in the traditional coated bolt method, improving ease of manufacture and operational flexibility.

Inventive Principle:

Principle #1Segmentation

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

This method ensures controlled and even contact, enhancing conductivity between fasteners and mating parts, improving the efficiency and reliability of the coating process.

Implementation Method 1

applying a pressurized fluid to the applicator tool to expand the expansion portion within the bore

Methodology Applied

Scientific EffectFluid pressure: Pressure Increase

Implementation Method 2

rotating the applicator tool to apply the coating material from the expansion portion to the bore

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentUS20250010333A1Applicator tools, methods and systems for coating a bore

Publication Date: 2025.01.09 THE BOEING CO

AI summary

An applicator tool for coating a bore includes a tubular body and an inflatable bladder. The tubular body includes a proximal end and a distal end opposing the proximal end along a longitudinal axis. The tubular body also includes an expansion portion proximate the distal end and an internal volume in relation to the expansion portion. The inflatable bladder disposed within the internal volume of the tubular body in relation to the expansion portion. A method for coating a bore includes inserting an expansion portion of an applicator tool into the bore. A coating material having been previously disposed on the expansion portion. The method also includes applying a pressurized fluid to the applicator tool to expand the expansion portion within the bore and rotating the applicator tool to apply the coating material from the expansion portion to the bore. A system that includes the applicator tool is also disclosed.