Insulated Fastener Cap Assembly for Lightweight Leak and Discharge Sealing
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Solution Overview
Problem
There is a need for an improved insulated and sealed cap to protect fastener components and substrate openings in aircraft from fluid leakage and electrical discharges, while maintaining minimal weight and structural integrity to withstand maintenance procedures.
Innovation Solution
A sealed cap assembly comprising a partially filled outer cap component with a curable sealant and an inner collet, which is assembled to fit loosely around a fastener component, with tapered ribs for locking, and a sealant material that forms a uniform insulation layer upon curing, providing a sturdy yet lightweight seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rigid and sturdy sealed cap is used to protect fastener components and substrate openings from fluid leakage and electrical discharges, then reliability and protection are improved, but weight increases
Solution Approach 1:
The sealed cap is divided into multiple components: an outer cap component, an inner collet, and a sealant material. This segmentation allows each component to be optimized for its specific function while using lightweight materials overall, achieving protection without excessive weight
Solution Approach 2:
The sealed cap utilizes composite construction combining the outer cap component, inner collet, and sealant material. This composite approach enables the structure to achieve the necessary strength and sealing reliability while minimizing weight through material optimization
2Reliability
If a sealed cap is designed to withstand normal maintenance procedures, then durability and reliability are improved, but device complexity increases
Solution Approach 1:
By segmenting the sealed cap into an outer cap component, inner collet, and sealant material, each part can be independently optimized for durability while the overall structure remains relatively simple. The segmented design allows for easy assembly and maintenance without requiring complex integrated structures
Solution Approach 2:
The inner collet is nested within the outer cap component, creating a compact and simple overall structure. This nesting arrangement allows the components to work together as a unified assembly that is durable during maintenance procedures without adding significant structural complexity
3Reliability
If a uniform insulation layer is extruded to seal the substrate opening, then sealing effectiveness is improved, but manufacturing precision requirements increase
Solution Approach 1:
The sealant material is designed to self-level and self-distribute uniformly when the outer cap component is pressed onto the substrate. This self-service mechanism eliminates the need for high-precision manufacturing of the insulation layer, as the material automatically achieves uniform sealing on its own
Solution Approach 2:
The sealant material undergoes a parameter change from a soft, moldable state during installation to a cured, rigid sealing layer. This parameter transformation allows the material to flow and distribute uniformly during application, then lock in place to provide reliable sealing without requiring high manufacturing precision
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 solution effectively seals and insulates fastener components and substrate openings against fluid leakage and electrical discharges, maintaining structural integrity and minimizing weight addition, while accommodating complex substrate geometries and providing a Faraday shield option for electrical protection.
Implementation Method 1
the outer cap component is then displaced toward the substrate to extrude the sealant material into a thin and substantially uniform insulation layer joined with an extruded outer bead on the substrate, and then permitted to cure
Implementation Method 2
the frozen insulated cap with the sealant material therein is thawed and preferably heated slightly before use
Implementation Method 3
the assembled insulated cap can be chilled and preferably frozen to prevent immediate curing of the sealant material until time for use
Data Source
AI summary
An insulated, sealed cap overlies and protects a fastener component or the like on a substrate in association with a substrate opening. The sealed cap includes an outer cap component filled partially with a selected sealant material and assembled with an inner collet sized and shaped to fit with a slip fit about the fastener component such as a nut or the like at one side of a selected substrate, such as the skin of an aircraft. An inboard edge of the inner collet seats on and substantially seals with the substrate. The outer cap component is then displaced toward the substrate to extrude the sealant material into a thin and substantially uniform layer joined with an extruded outer bead on the substrate, and then permitted to cure. Tapered ribs on the inner collet effectively lock with the outer cap component during sealant material curing and subsequently.