Spark Containment Cap Assembly Without Rear-Side Access
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Solution Overview
Problem
Existing spark containment cap systems require access to the rear side of a structure for assembly, which complicates the installation process and increases the risk of sparking during lightning strikes on aircraft.
Innovation Solution
A spark containment cap with a base that provides an adhering surface, allowing the cap to be fixed in place before drilling, and a sacrificial portion for receiving the fastener, enabling one-sided drilling and assembly without rear access.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the spark containment cap is installed after drilling and fastener insertion, then the fastening process can be completed, but rear access is required which complicates the assembly process
Solution Approach 1:
The spark containment cap is installed on the structure before drilling and fastener insertion. The cap includes a sacrificial portion that is removed during drilling to create an opening for the fastener, eliminating the need for rear access and simplifying the assembly process.
2Reliability
If the spark containment cap encloses the fastener end, then spark containment is provided, but the assembly requires rear access which increases complexity
Solution Approach 1:
The cap is pre-installed on the structure before fastening operations. The sacrificial portion is designed to be removed during drilling, allowing the fastener to pass through while the remaining cap structure encloses and protects the fastener end, providing spark containment without requiring rear access.
Solution Approach 2:
The sacrificial portion is extracted from the cap structure during the drilling process. This removed portion allows the fastener to pass through the cap, while the remaining cap body continues to provide spark containment for the enclosed fastener end.
3Object-affected harmful factors
If traditional spark containment caps are used, then lightning strike protection is provided, but assembly requires access to both sides of the structure
Solution Approach 1:
The cap is installed on the accessible side of the structure before drilling. The sacrificial portion is removed through drilling from the same side, and the fastener is inserted through the created opening. This eliminates the need for rear access while maintaining lightning strike protection through the enclosed fastener end.
Data Source
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.