Removable Fastener Recess Insert for Coated Surfaces
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Solution Overview
Problem
Existing fastening systems with tool recesses filled with fairing materials or conformal coatings become difficult to remove, leading to tedious and ineffective manual removal processes that can result in stripping of recess details.
Innovation Solution
A removable insert with a shape matching the tool recess is used, allowing easy access and removal even under coated surfaces by providing an interference fit and being made of elastic materials like plastic, which can be fabricated using processes such as selective laser sintering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If fairing material or conformal coating is applied to fill the tool recess of a fastener, then a smooth surface is achieved, but the fastener becomes difficult to remove and manual removal is required which is tedious and time-consuming
Solution Approach 1:
The tool recess is segmented into two functional zones: an upper portion filled with fairing material for surface smoothness, and a lower portion containing a removable insert that maintains access to the recess. This segmentation allows the fastener head to serve dual purposes - providing a smooth exterior surface while preserving tool access capability for future removal.
Solution Approach 2:
A removable insert acts as an intermediary element within the tool recess. This insert provides a interface that allows removal tools to access the recess through the fairing material, serving as a mediator between the smooth surface requirement and the tool access requirement.
2Ease of operation
If manual removal of fairing material is performed to access the tool recess, then the fastener can be removed, but the process is ineffective and can result in stripping of the recess detail
Solution Approach 1:
The removable insert is pre-installed in the tool recess before the fastener is subjected to service conditions. This preliminary action ensures that when removal is needed, the insert is already in place to guide the removal tool, preventing damage to the recess details and eliminating the need for destructive manual removal of fairing material.
3Volume of stationary object
If the insert thickness is equal to the recess depth, then complete filling of the recess is achieved, but the insert may interfere with the fairing material application
Solution Approach 1:
The insert thickness parameter is optimized to be slightly less than the full recess depth. This parameter change allows the fairing material to be applied over the insert without interference, while still providing sufficient depth for the insert to maintain structural integrity and provide effective tool access. The fairing material can then flow over the insert surface without air pockets or application defects.
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 easy and non-destructive removal of fasteners from coated surfaces, maintaining recess integrity and allowing smooth surface maintenance without damaging the surrounding material.
Implementation Method 1
made of elastic materials like plastic
Data Source
AI summary
A fastening system includes a fastener having a head portion and a shaft portion, wherein the head portion has a recess (e.g., a removal tool recess), and an insert (e.g., a plastic insert) having an insert shape substantially equal to the recess shape and an insert thickness substantially equal to or less than the recess depth, wherein the insert is configured to removeably seat within the recess of the head portion. In this way, the insert may be later removed from the recess, allowing easy tool access even in applications where an overlying fairing material or other such conformal coating is used.