Maverick Igniter Cable Saver: Friction-Fit Clip for Chafing Reduction

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Solution Overview

Problem

The installation of igniter cables into aircraft umbilical housing slots is challenging due to chafing caused by the metal slots, leading to cable degradation and high replacement costs, as ground crews often use forceful methods to insert and remove the cables.

Innovation Solution

A clip with outwardly flaring tabs that friction-fit into the umbilical slot groove, securely holding the igniter cable in place and preventing chafing, made from heat-treated acrylonitrile butadiene styrene (ABS) to withstand temperature variations and prevent foreign object damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If forceful methods are used to insert and remove igniter cables from metal slots, then installation and removal can be completed, but cable chafing and degradation occur

Engineering Contradiction:

Improveease of cable installationVSAvoidcable chafing

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The patent introduces a protective sleeve as an intermediary component between the igniter cable and the metal slot. This sleeve acts as a mediator that prevents direct contact between the cable and the chafing metal surfaces, allowing installation and removal operations to proceed without damaging the cable.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The protective sleeve is installed on the cable beforehand to provide cushioning and protection before the cable is inserted into the metal slot. This pre-protection prevents chafing during the installation and removal processes, eliminating the need for forceful methods that would otherwise damage the cable.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Reliability

If igniter cables are held directly in metal umbilical slots, then secure positioning is achieved, but cable degradation occurs due to chafing

Engineering Contradiction:

Improvecable positioning stabilityVSAvoidcable degradation

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The protective sleeve serves as an intermediary between the cable and the metal slot, maintaining the secure positioning function while eliminating the harmful chafing effect. The sleeve interfaces with the metal slot to provide stability, while its protective surface prevents direct contact and damage to the cable.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The protective sleeve is made from a composite or specially formulated material that combines properties of flexibility, friction-fit capability, and protection. This material provides both the mechanical interface needed for secure positioning and the protective qualities needed to prevent cable degradation.

Inventive Principle:

Principle #40Composite materials

3Productivity

If blunt objects are used to force cables into slots, then installation can be completed, but cable chafing increases

Engineering Contradiction:

Improveinstallation completionVSAvoidcable chafing

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

By installing the protective sleeve beforehand, the cable is cushioned and protected before insertion occurs. This eliminates the need to use blunt objects to force the cable into the slot, as the sleeve provides the necessary interface that allows smooth insertion without damage.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The protective sleeve acts as an intermediary that facilitates the installation process without requiring forceful methods. It provides the mechanical interface needed for insertion while protecting the cable from the harmful effects of using blunt objects or excessive force.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 clip significantly reduces cable chafing and replacement costs by providing a secure, friction-fit interface that survives temperature extremes and is cost-effective, even if used as a one-time device.

Implementation Method 1

made from heat-treated acrylonitrile butadiene styrene (ABS) to withstand temperature variations

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Implementation Method 2

A clip with outwardly flaring tabs that friction-fit into the umbilical slot groove, securely holding the igniter cable in place

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentUS9581110B1Maverick igniter cable saver

Publication Date: 2017.02.28 THE UNITED STATES OF AMERICA AS REPRESENTED BY THE SECRETARY OF THE NAVY

AI summary

A maverick igniter cable saver employs a longitudinal housing having a first portion, a second portion, an outer surface, an inner surface, a forward end, and an aft end. The inner surface of the first portion is configured to snap fasten substantially around an igniter cable. The second portion has off-setting tapered tabs. Each of the tapered tabs has a proximal end and a distal end. The distal ends are interfaces configured to friction-fit in an umbilical slot groove.