Split Ring Wire Bundle Seal Sleeve for Consistent Feedthrough Sealing
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Solution Overview
Problem
Existing methods for electrical feedthroughs in aircraft are prone to human-induced variability, are time-consuming, costly, and difficult to modify or repair without disassembling cabin monuments, leading to issues with air pressure sealing and wire bundle diameter tolerance.
Innovation Solution
A split ring wire bundle seal sleeve made from durable, non-hygroscopic glass fiber reinforced plastic with snap-fit latch mechanisms and sealant putty gripping ridges, which compresses to create a pressure-resistant seal around wiring, reducing human error and installation time, and allowing for flexible configurations compatible with various wire diameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If hand-fitted feedthroughs are used, then flexibility in installation is achieved, but human-induced variability results in inconsistent sealing quality
Solution Approach 1:
The feedthrough assembly is divided into modular components: a bulkhead section, a sleeve section, and a sealant component. This segmentation allows each part to be manufactured with precise tolerances independently, eliminating human variability while maintaining installation flexibility through the modular assembly process.
Solution Approach 2:
The invention transitions from variable human hand-fitting to a standardized assembly process with controlled parameters. The sleeve includes predefined features such as snap-fit latch mechanisms, ridges for sealant positioning, and retaining features that ensure consistent sealing quality regardless of installer skill level.
2Reliability
If traditional feedthrough assembly methods are used, then complex sealing operations can be performed, but excessive time is required due to trial and error
Solution Approach 1:
The sleeve is pre-configured with all necessary features before assembly: snap-fit latch mechanisms are pre-positioned, ridges are molded in to guide sealant placement, and retaining features are integrated. This preliminary preparation eliminates trial-and-error during installation, ensuring complete sealing operations are performed correctly on the first attempt.
Solution Approach 2:
The snap-fit latch mechanism automatically engages when the sleeve is compressed onto the wire bundle, providing self-verifying assembly. The ridges self-align the sealant in the correct position, and the retaining features automatically prevent over-compression or misalignment, eliminating the need for operator judgment and reducing assembly time.
3Adaptability or versatility
If wire bundles are installed late in the process, then wiring flexibility is maintained, but out-of-tolerance diameters are discovered too late for correction
Solution Approach 1:
The sleeve and bulkhead are assembled with precision features before wire bundle installation. The snap-fit latches and retaining features are pre-positioned to define exact tolerance boundaries. When wire bundles are later installed, the predefined features provide immediate visual and mechanical verification of diameter tolerance, allowing correction before final assembly.
4Strength
If permanent feedthrough installations are used, then structural integrity is maintained, but removal or reconfiguration requires disassembly of cabin monuments
Solution Approach 1:
The feedthrough is designed as a modular assembly with distinct bulkhead and sleeve sections connected by snap-fit latches. This segmentation maintains structural integrity during service while enabling easy separation for removal or reconfiguration. The modular design allows the sleeve to be detached from the bulkhead without damaging either component or requiring monument disassembly.
Solution Approach 2:
The snap-fit latch mechanism provides a dynamic connection that transitions from a locked, structurally-integral state during operation to an easily separable state for maintenance. The latches can be released by simple manual action, transforming the permanent-looking installation into a serviceable component without compromising structural integrity during normal use.
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 solution eliminates human variability, reduces installation time by 52 minutes, and simplifies the process by eliminating the need for repetitive measurements and tools, providing a consistent, air-tight seal that is easier to maintain and modify without disassembling the cabin monuments.
Implementation Method 1
The action of squeezing the sleeve halves together compresses the putty and creates a pressure resistant seal between the wires
Implementation Method 2
The sleeves internal ridges retain the putty and prevent air pressure from forcing it out of the sleeve
Implementation Method 3
compressing the charge of sealant putty until the first snap-fit latch mechanism and the second snap-fit latch mechanism engage together, and creating a pressure resistant seal between the set of wires
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
The present disclosure includes a split ring wire bundle seal sleeve and an assembly technology for pressurized electrical feedthroughs. A kit of parts is also described.