Protective Seal Cap Ribs for Friction-Held Fastener Installation
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Solution Overview
Problem
The installation of protective seal caps on structures, such as aircraft, is time-consuming and prone to defective installations due to the need for manual holding to ensure proper seating and decompression of sealant, especially in orientations affected by gravity, leading to increased failure rates and reinstallation needs.
Innovation Solution
A protective seal cap assembly with a cap member featuring a sidewall and interior space, including ribs that extend along the central axis, which deform to create interference friction with the fastener, maintaining the cap in position against the structure and preventing separation, even when the installer is not present.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the installer manually holds the protective seal cap in position to ensure proper seating and decompression of sealant, then the quality of installation is improved, but the installation time increases and labor cost increases
Solution Approach 1:
The protective seal cap is designed with an integrated retention mechanism that automatically holds the cap in position on the structure without requiring manual holding by the installer. The retention mechanism engages with the fastener end portion to maintain proper seating and allows sealant decompression without continuous human intervention, thereby improving installation quality while reducing installation time and labor requirements
Solution Approach 2:
The retention mechanism is pre-configured on the protective seal cap before installation begins. This preliminary setup ensures that as soon as the cap is positioned on the structure, the retention mechanism automatically engages to hold it in place, eliminating the need for the installer to continuously hold the cap during the sealant decompression process
2Adaptability or versatility
If the protective seal cap is positioned in orientations affected by gravity (upside down, vertical, or inclined), then the installation versatility is improved, but the cap may move or separate resulting in installation failure
Solution Approach 1:
The retention mechanism automatically adapts to various gravitational orientations through its friction-based engagement with the fastener end portion. The mechanism uses interference friction and normal forces that remain effective regardless of whether the cap is installed horizontally, vertically, upside down, or on an inclined surface, eliminating the need for installer intervention to counteract gravity in different positions
Solution Approach 2:
The design replaces the mechanical system of manual holding and positioning with a passive friction-based retention mechanism. This mechanism uses interference friction between the retention component and the fastener end portion, along with normal forces from the cap geometry, to maintain secure attachment without requiring active mechanical intervention from the installer during sealant curing
3Manufacturing precision
If the installer must hold the protective seal cap for sufficient time for sealant decompression, then the installation quality is improved, but the installation process becomes more demanding and costly
Solution Approach 1:
The retention mechanism is an integrated feature of the protective seal cap itself, requiring no additional tools, devices, or complex procedures. The mechanism automatically maintains the cap in position during sealant decompression through its friction-based engagement with the fastener, simplifying the installation process while ensuring proper sealant decompression quality
Solution Approach 2:
The retention mechanism acts as an intermediary between the protective seal cap and the fastener end portion. It provides the necessary holding force during sealant decompression through interference friction and normal forces, enabling reliable sealant curing without requiring complex installation procedures or additional equipment
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 interference friction ensures a secure and efficient installation process, reducing the time and cost of installation, and improving the quality of installations by maintaining the cap in place during sealant curing regardless of orientation, thus minimizing reinstallation requirements.
Implementation Method 1
deforming at a least a portion of the at least one rib creating interference friction between the at least one rib and the end portion of the fastener
Data Source
AI summary
A protective seal cap assembly for enclosing an end portion of a fastener extending through a structure, which includes a cap member. The cap member includes a sidewall which defines an opening and defines an interior space within the sidewall and aligned with the opening, wherein the sidewall defines a central axis. The cap member further includes at least one rib which extends away from an interior surface of the sidewall within the interior space and extends in a direction along the central axis of the cap member.