Seal Molding System for Aircraft Bulkhead Fittings
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Solution Overview
Problem
Manual application of sealant to electrical connectors on aircraft bulkheads is laborious, inconsistent, and results in a rough surface finish, leading to reduced product quality and increased rework.
Innovation Solution
A seal molding system with a mold body having a geometry complementary to the fitting and panel, featuring an injection hole for sealant and a vent hole for air and sealant, allowing for efficient and consistent sealing by injecting sealant into a mold cavity and allowing it to cure before removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual application of sealant is used, then the sealing process can be performed with simple tools, but the process is laborious and time-consuming
Solution Approach 1:
The patent replaces manual mechanical application of sealant with an automated injection molding system. A mold body with an injection hole delivers sealant into the mold cavity automatically, eliminating the need for manual application with hand implements. This substitution of mechanical manual operation with an automated injection system resolves the contradiction by maintaining simplicity while dramatically improving productivity.
2Device complexity
If manual application of sealant is used, then the process requires minimal equipment, but the results are inconsistent across different installations
Solution Approach 1:
The injection molding system replaces manual application with an automated mechanism that injects sealant into a precisely fitted mold cavity. The mold body is formed complementary to the fitting, ensuring consistent geometry and sealant distribution across all installations. This automated system eliminates human variability while maintaining relatively simple equipment consisting of a mold body and injection hole.
Solution Approach 2:
The patent controls the sealing process by maintaining specific parameters: the mold cavity is completely filled with sealant, the mold body is formed with precise complementary geometry to the fitting, and the sealant is allowed to cure completely before removal. These controlled parameters ensure consistent sealing results across different installations while using straightforward equipment.
3Adaptability or versatility
If manual application of sealant is used, then the process is flexible and adaptable, but the surface finish is rough and may require rework
Solution Approach 1:
The injection molding system replaces manual application with an automated process that produces a smooth surface finish. The sealant is injected into a mold cavity formed complementary to the fitting, and the mold base engages the panel surface to define the cavity boundaries. This process produces a consistent, smooth exterior surface that eliminates the rough finish and potential rework associated with manual application, while the system remains adaptable to different fitting configurations.
4Productivity
If automated injection molding is used, then productivity and consistency are improved, but the device complexity increases
Solution Approach 1:
The mold body is segmented into functional components: a mold body portion with an injection hole, a mold cavity formed complementary to the fitting, and a mold base with a base portion that engages the panel surface. This segmentation allows each component to perform its specific function while keeping the overall device relatively simple. The injection hole delivers sealant, the cavity defines the seal geometry, and the base provides support and engagement with the panel.
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
Significantly reduces labor by over 90% compared to manual methods, providing a high-quality, smooth surface finish that is consistently reproduced across multiple installations.
Implementation Method 1
injecting sealant into an injection hole formed in the mold body until the sealant substantially fills a mold cavity
Implementation Method 2
The sealant may be allowed to cure, after which the mold body may be removed from the fitting
Data Source
Figure 1
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AI summary
A seal molding system (400) for forming a seal (300) around a fitting (200) mounted to a panel (114), comprising: a mold body (402) having a mold inner geometry (404) formed complementary to a fitting outer geometry (228) of a fitting (200); the mold body (402) having a mold base (406) formed complementary to a panel surface (116); and the mold body (402) including an injection hole (420) for injecting sealant (316) into a mold cavity (416), and a vent hole (422) for venting air and sealant (316) from the mold cavity (416), wherein the mold body (402) is comprised of: a fixed base portion (502) having a base portion inner geometry (504) configured complementary to a fitting base (230); a rotatably adjustable top portion (518) being mountable on top of the fixed base portion (502) and having a top portion inner geometry (520) configured complementary to a rotatable fitting feature (218) being rotatably engaged to the fitting base (230); and the rotatably adjustable top portion (518) being rotatable relative to the fixed base portion (502) for clocking the top portion inner geometry (520) into alignment with the rotatable fitting feature (218).