Seal Cap Form for Precise Fastener Sealing Without Slumping
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional seal caps for fasteners in fuel receptacles, such as those in aircraft, face challenges in meeting critical dimensional requirements due to slumping of uncured sealant and require time-consuming installation and inspection processes, often necessitating rework.
Innovation Solution
A form comprising non-metallic solidified material with distal and proximal axial openings and a lateral wall with through openings is used to guide and constrain viscous sealant, ensuring consistent coverage and desired configuration, allowing the form to be abandoned after seal formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If seal caps are formed by manually discharging viscous curable sealant over each fastener, then the process is simple, but the seal caps do not meet critical dimensional requirements due to slumping of uncured sealant
Solution Approach 1:
A form made of non-metallic solidified material is introduced as an intermediary device to shape the viscous sealant during curing. The form acts as a mold that guides and constrains the sealant to achieve precise dimensional requirements while maintaining manufacturing simplicity
Solution Approach 2:
The invention changes the physical state parameters of the sealant by controlling its curing process within the form. The sealant transitions from a viscous state (prone to slumping) to a solidified state (maintaining dimensional precision) through controlled curing within the confining form
2Manufacturing precision
If seal caps utilize a pre-cured exterior shell, then dimensional precision is improved, but installation time increases due to multiple time-consuming steps
Solution Approach 1:
The form is prepared in advance and placed about the fastener before sealant application. This preliminary positioning of the form eliminates the need for time-consuming post-application adjustments, smoothing, and inspection that were required with pre-cured shells
Solution Approach 2:
The form is abandoned in place after seal formation, eliminating the need for removal and extensive inspection. This disposable approach to the forming device significantly reduces manufacturing cycle time compared to reusable pre-cured shells that require careful handling and inspection
3Reliability
If conventional seal caps are installed using pre-cured shells with viscous sealant, then sealing function is achieved, but rework is necessary due to squeezed-out sealant and entrapped air
Solution Approach 1:
The form serves as a mediator that controls sealant flow and prevents defects. By confining the sealant within the form boundaries during curing, the form prevents squeezed-out sealant and eliminates entrapped air, ensuring reliable sealing without complex installation procedures
Solution Approach 2:
The form controls the physical parameters of the sealant during curing, maintaining proper viscosity and flow characteristics until the sealant sets. This controlled environment prevents the sealant from squeezing out and eliminates air entrapment, achieving reliable seals with simple installation
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 simplifies the seal formation process, reduces manufacturing cycle time, and ensures accurate sealing without the need for extensive rework, thereby improving efficiency and cost-effectiveness in sealing fasteners within fuel receptacles.
Implementation Method 1
supporting a volume of a viscous substance encapsulating at least a portion of an object, protruding through a substrate, while the viscous substance solidifies to form a seal
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
One example of the present disclosure relates to a form (100) for supporting a volume of a viscous substance encapsulating at least a portion (107) of an object (12) while the viscous substance solidifies to form a seal (10). The form (100) comprises a non-metallic solidified material (102); a distal axial opening (104); a proximal axial opening (106); and a lateral wall (108) between the distal axial opening (104) and the proximal axial opening (106). The lateral wall (108) comprises an outwardly facing surface (111) having a surface area, and at least one through lateral opening (110). (Fig. 1)