Spring-Loaded Seal Cap for Fastener Electromagnetic Insulation
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Solution Overview
Problem
Existing methodologies for covering protruding fasteners with insulating caps are labor-intensive and time-consuming, particularly when requiring internal and external application of sealant to inhibit electromagnetic energy and hot particle discharge.
Innovation Solution
A system comprising a cap with an interior, a base, pawls, and a tooth configured to positively engage the fastener, along with a method involving the injection of sealant through a port system to facilitate efficient and automated cap installation over fasteners, reducing manufacturing time and enhancing electromagnetic insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sealant is applied internally and externally to cover protruding fasteners, then electromagnetic energy and hot particle discharge are inhibited, but labor intensity and time consumption increase
Solution Approach 1:
The cap system performs self-sealing through the spring-loaded seal that automatically engages with the recessed surface when the cap is installed. The seal is compressed by the spring force between the cap's base and the recessed surface, creating an automatic seal without requiring manual application of sealant, thus eliminating the labor-intensive sealing process while maintaining electromagnetic insulation effectiveness
Solution Approach 2:
The patent extracts the sealant application step from the fastener covering process by using a mechanical seal system instead. The seal is integrated into the cap structure itself, removing the need for separate sealant application steps (both internal and external) and replacing them with a single mechanical sealing action that occurs during cap installation
2Object-affected harmful factors
If traditional cap installation methods are used, then electromagnetic discharge is inhibited, but installation time and labor requirements increase
Solution Approach 1:
The seal is pre-loaded with spring force during cap manufacturing, so that when the cap is installed over the fastener, the seal automatically engages with the recessed surface without requiring additional sealing operations. The spring mechanism is pre-positioned to ensure immediate sealing contact upon cap installation, eliminating time-consuming manual sealing steps
Solution Approach 2:
The cap is designed to nest over the protruding fastener, with the seal integrated within the cap structure. The seal is positioned inside the cap's base area and engages with the recessed surface on the fastener, creating a nested configuration where the seal is housed within the cap assembly. This nested design allows the seal to be compressed between the cap base and the recessed surface, achieving automatic sealing during the single action of installing the cap over the fastener
Data Source
AI summary
A cap for use in covering a portion of a fastener protruding from a surface is provided. The portion includes threads. The cap includes an interior, a base that at least partially delimits the interior, a threaded receptacle on the interior configured to threadably engage the portion of the fastener, and a seal coupled to the base to engage the surface.