Split Ring Seal Sleeve for Consistent Wire Feedthrough Assembly
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Solution Overview
Problem
Existing methods for sealing electrical feedthroughs in aircraft are prone to human-induced variability, time-consuming, costly, and create assembly issues, particularly with wire bundle diameters that are often discovered late in the assembly process, and are difficult to remove or reconfigure.
Innovation Solution
A split ring wire bundle seal sleeve made of durable, non-hygroscopic glass fiber reinforced plastic, featuring snap-fit latches and sealant gripping ridges, which compresses sealant putty to create a pressure-resistant seal around wiring, reducing human error and installation time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If hand-fitted feedthrough assembly methods are used, then flexibility in installation is maintained, but human-induced variability increases and consistency decreases
Solution Approach 1:
The feedthrough assembly is divided into modular components: a monolithic feedthrough body, separate wire bundle seals, and distinct sealing elements. This segmentation allows each component to be manufactured with high precision independently, then assembled with consistent results, eliminating hand-fitting variability while maintaining installation flexibility.
Solution Approach 2:
The invention specifies precise geometric parameters for the feedthrough body bore, wire bundle seal dimensions, and sealing element properties. By controlling these parameters within tight tolerances during manufacturing, the system achieves consistent sealing performance across all installations without requiring manual adjustment.
2Adaptability or versatility
If traditional feedthrough assembly methods are used, then complex adjustments can be made, but assembly time increases excessively
Solution Approach 1:
The wire bundle seals are pre-formed with specific geometries and the sealing elements are pre-configured to match the feedthrough body bore dimensions. This preliminary preparation eliminates the need for time-consuming trial and error adjustments during final assembly, as components are designed to fit together in a single operation.
Solution Approach 2:
The system incorporates flexible sealing elements that can dynamically adapt to slight variations in wire bundle diameter and shape. This dynamic adaptation capability provides adjustability without requiring multiple manual adjustments, achieving both versatility and speed.
3Productivity
If out of tolerance wire bundle diameters are not detected early, then assembly proceeds, but major problems occur during final installation
Solution Approach 1:
The system incorporates measurement and feedback mechanisms to detect wire bundle diameter and dimensional tolerances before final assembly. This early detection provides feedback that allows correction or rejection of out-of-tolerance wire bundles, preventing assembly problems later while maintaining overall assembly flow.
Solution Approach 2:
Dimensional verification and tolerance checking are performed as preliminary actions before the wire bundles are committed to final assembly. This preliminary quality check ensures only in-tolerance wire bundles proceed to assembly, guaranteeing final assembly success while maintaining productivity through early detection.
4Reliability
If traditional feedthroughs are installed, then sealing is achieved, but removal and reconfiguration are costly and difficult
Solution Approach 1:
The feedthrough system is segmented into removable components: the wire bundle seals and sealing elements can be detached from the monolithic feedthrough body without removing the feedthrough from the aircraft structure. This segmentation enables easy repair and reconfiguration while maintaining sealing effectiveness through the use of reusable sealing elements.
Solution Approach 2:
The design allows the sealing elements to be discarded or recovered independently of the feedthrough body. Sealing elements can be recovered and reused in new locations, or discarded if damaged, while the expensive feedthrough body remains installed in the aircraft, significantly reducing repair costs.
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 split ring sleeve provides a consistent, efficient, and cost-effective sealing solution that minimizes installation time, reduces human variability, and allows for easy repair or reconfiguration without disassembling vehicle components.
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
Data Source
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.