Threaded Anchoring Washer Cap for Fastener Electrical Isolation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical insulation cap assemblies for metallic fasteners are time-consuming to install and require tedious smoothing of excess sealant, and lack a reliable securement mechanism, especially in critical areas like aircraft fuel tanks and sensitive electronic equipment, where they are prone to slumping or lifting during the curing process.
Innovation Solution
A cap system with a securement mechanism featuring threads and tabs around the washer periphery, allowing for easy engagement and secure positioning of the cap member, which includes a nonconductive material and sealant to ensure electrical isolation, and a design that prevents excess sealant expulsion and simplifies the installation process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional sealant caps are filled with liquid sealant material, then electrical insulation and sealing are achieved, but excess sealant must be smoothed out which is tedious and time consuming
Solution Approach 1:
The patent extracts the problematic excess sealant from the system by providing controlled exit paths (gap between cap and washer, or through openings in the cap) where excess sealant can be discharged away from the critical joint area, eliminating the need for time-consuming smoothing operations while maintaining sealing integrity
Solution Approach 2:
The patent introduces an intermediary mechanism (the gap between cap and washer, or openings in the cap) that mediates between the sealant filling process and the final sealed joint, allowing excess sealant to be safely redirected to a designated discharge area rather than requiring manual removal
2Manufacturing precision
If the cap is held in place during curing to prevent slumping or lifting, then proper positioning is maintained, but the process requires additional time and quality checks
Solution Approach 1:
The patent applies preliminary action by providing pre-designed support mechanisms (tabs extending from the cap or structure, or interlocking features) that automatically maintain cap positioning during the curing process, eliminating the need for continuous monitoring and manual adjustment
Solution Approach 2:
The patent implements self-service through self-supporting structural features (rigid tabs, interlocking mechanisms) that automatically maintain the cap's position during curing without requiring external intervention or quality checks, making the process self-regulating
3Reliability
If a securement mechanism is added to the cap system, then reliable attachment is achieved, but device complexity increases
Solution Approach 1:
The patent applies universality by designing tabs and securement features that serve multiple functions: they provide structural support during curing, enable mechanical attachment to the structure, and can facilitate alignment during installation, thereby achieving reliable securement without proportionally increasing complexity
Solution Approach 2:
The patent segments the securement function into discrete, simple elements (individual tabs extending from the cap or structure) rather than requiring a complex integrated mechanism, allowing each tab to independently contribute to overall securement reliability
Data Source
AI summary
A cap system for enclosing a metallic fastener assembly extending through a structure includes a first securement mechanism positioned about a periphery of a washer of the metallic fastener assembly wherein the first securement mechanism includes threads. The cap system further includes a cap member including a sidewall having an inner surface which defines a cavity dimensioned to receive the washer and defines a second securement mechanism complementary configured to engage the first securement mechanism positioned about the periphery of the washer. An end of the sidewall of the cap member defines an opening which provides the washer to have access into the cavity.