Self-Holding Seal Molding System for Aircraft Panel Sealing
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Solution Overview
Problem
Existing methods for sealing electrical connectors to aircraft panels are laborious, produce inconsistent results, and require clamping devices that can be difficult to install and separate in confined spaces, leading to a need for a more efficient and consistent sealing system.
Innovation Solution
A self-holding and self-extracting seal molding system comprising a mold body and mold collar with complementary geometries, allowing for axial and rotational motion to secure and remove the sealant without clamping devices, ensuring a smooth surface finish and consistent sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual application of sealant is used, then the sealing process can be performed without specialized equipment, but the process is laborious and time-consuming with rough surface finish and inconsistent results
Solution Approach 1:
The mold collar is designed to automatically perform multiple functions: it centers the mold body on the fitting, applies axial load to secure the mold body against the panel, and facilitates extraction after curing. The self-threading mechanism and bearing surfaces enable the system to self-adjust and self-service without external clamping devices or manual intervention during the sealing process.
2Reliability
If multi-part molds with clamping devices are used, then the seal can be formed around the connector body, but the installation of clamping devices is time-consuming and may not be possible in confined areas
Solution Approach 1:
The invention extracts and eliminates the clamping devices from the traditional multi-part mold system. The mold collar performs the clamping function through its self-threading engagement with the fitting and bearing surfaces that convert rotational motion to axial load, removing the need for separate clamping mechanisms and reducing installation complexity and time.
Solution Approach 2:
The mold collar serves multiple functions simultaneously: it acts as a centering mechanism, a clamping device, a load application mechanism, and an extraction tool. This multi-functionality consolidates what would traditionally require multiple separate components into a single integrated element, eliminating the need for clamping devices while maintaining seal formation capability.
3Reliability
If multi-part molds are used, then the seal can be formed, but the separation of molds from the cured seal is difficult due to stiction between the cured seal and the inner mold surfaces
Solution Approach 1:
The invention inverts the traditional mold separation approach. Instead of the mold actively pulling away from the cured seal, the mold collar threads onto the fitting and uses the fitting itself as the extraction mechanism. The bearing surfaces convert rotational motion into axial motion that automatically extracts the mold body from the cured seal, making separation easy and eliminating stiction problems.
4Device complexity
If a single-piece mold body is used, then the device complexity is reduced, but the ability to apply axial load and facilitate extraction is limited
Solution Approach 1:
The invention introduces dynamic elements to the simple mold body through the mold collar assembly. The bearing surfaces between the mold collar and mold body enable dynamic conversion of rotational motion to axial motion, allowing the system to apply and release axial loads as needed. This dynamic mechanism maintains structural simplicity while providing the necessary force application and extraction capabilities.
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 system enables efficient, time-saving, and consistent sealing around fittings with a smooth surface finish, eliminating the need for clamping devices and facilitating easy removal of the seal molding system from the cured seal.
Implementation Method 1
The mold collar has a mold collar threaded portion configured to be threadably engaged to a fitting threaded portion of the fitting
Implementation Method 2
The mold collar includes a bearing surface configured to bear against a bearing surface of the mold body. Rotation of the mold collar relative to the mold body in a first rotational direction causes the bearing surface of the mold collar to bear against the bearing surface of the mold body, causing axial motion of the mold collar in a first axial direction that urges the mold body against the panel surface
Implementation Method 3
injecting sealant into an injection hole in the mold body for filling a mold cavity enclosed by the mold body inner geometry, the fitting outer geometry, and the panel surface
Data Source
AI summary
A seal molding system includes a mold body having a mold body inner geometry configured complementary to a fitting outer geometry of a fitting, and a mold collar having one or more mold collar engagement elements configured to engage with one or more fitting engagement elements. The mold collar is couplable to the mold body at a body-collar interface allowing free rotation of the mold collar relative to the mold body. The body-collar interface is configured such that axial motion in a first axial direction and/or rotational motion in a first rotational direction of the mold collar relative to the fitting causes the mold collar to urge the mold body against a panel surface, and axial motion in a second axial direction and/or rotational motion in a second rotational direction of the mold collar relative to the fitting causes the mold collar to draw the mold body away from the panel.