Spark Containment Cap for One-Sided Fastener Assembly
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Solution Overview
Problem
Existing spark containment caps for fasteners in aircraft require access to the rear side of the panel after drilling and fastening, complicating the assembly process and increasing the risk of sparking and ignition due to lightning strikes on metallic fasteners.
Innovation Solution
A spark containment cap with a base and cover portion that can be adhered to a structure before drilling, allowing one-sided assembly and eliminating the need for precise alignment, manufactured through blow molding for cost-effectiveness and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If spark containment caps are installed after drilling and fastening, then lightning protection is achieved, but assembly complexity increases and productivity decreases
Solution Approach 1:
The spark containment cap is installed on the fastener before the fastening operation, allowing the cap to be pre-positioned and secured while the fastener is being installed through the panel, eliminating the need for separate post-assembly operations
2Reliability
If spark containment caps are installed after drilling and fastening, then lightning protection is achieved, but device complexity increases
Solution Approach 1:
The spark containment cap installation is merged with the fastener installation process, where the cap is attached to the fastener shaft and installed simultaneously with the fastener itself, reducing the number of separate operations and tools required
3Manufacturing precision
If access to rear side of panel is required for cap installation, then proper cap positioning is achieved, but assembly time increases
Solution Approach 1:
The spark containment cap is pre-attached to the fastener shaft before insertion, allowing the entire assembly to be installed from one side of the panel, eliminating the need for rear access while maintaining proper positioning through the pre-established connection
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 quicker, simpler, and more efficient assembly by enabling one-sided drilling and fixing of fasteners, reducing the risk of sparking and ignition, and optimizing space usage in aircraft structures.
Implementation Method 1
The base providing an adhering surface for adhering the spark containment cap to a structure
Data Source
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AI summary
A spark containment cap for enclosing an end of a fastener protruding from a structure; the enclosed body having a base and a cover portion; the cover portion extending from the base; the base providing an adhering surface for adhering the spark containment cap to a structure; and the base and the cover portion together forming a cavity within the enclosed body inside which the end of a fastener can be enclosed.