Systems and methods for making and using a fitted cap for applying a shaped sealant shroud to a portion of a fastener

• US 10,458,456 B2
• Filed: 12/22/2017
• Issued: 10/29/2019
• Est. Priority Date: 12/22/2017
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Pillay, Ganesh R.
• Primary Examiner(s): Vaughan, Jason L
• Application Number:
  US15/853,094
• Publication Number:
  US 20190195267A1
• Time in Patent Office: 676 Days
• CPC Class Codes: B05C 11/02 Apparatus for spreading or distributing liquids or other fluent materials already applied to a surface ; Controlling means thereforB05C7/00 takes precedence; Hand tools for such purposes B05C17/10; Control of the thickness of a coating by spreading or distributing liquids or other fluent materials already applied to the coated surfacecontrolling supply of liquid or other fluent material B05C11/10
• CPC Class Codes: B05C 17/00516 Shape or geometry of the outlet orifice or the outlet element
• CPC Class Codes: B64C 1/061 Frames
• CPC Class Codes: B64F 5/10 Manufacturing or assembling aircraft, e.g. jigs therefor
• CPC Class Codes: B64F 5/40 Maintaining or repairing aircraft
• CPC Class Codes: F16B 33/004 Sealing; Insulation by means of washers F16B43/001
• CPC Class Codes: F16B 37/14 Cap nuts; Nut caps or bolt caps

Abstract

A system (501) for applying a shaped sealant shroud (590) to a portion (106) of a fastener (100) comprises a fitted cap (300) positionable such that a uniform gap (302) is formed between a wall (305) of the cap and the portion (106) of the fastener (100). The fitted cap (300) further comprises an inlet opening (306) and a vent (309) each configured to be communicatively coupled with the uniform gap (302). The system (501) also comprises a cap-manipulation tool (500) comprising a shaft (510) comprising a through, circumferentially closed, channel (516), configured to receive sealant (592) and to communicate the sealant (592) therethrough. The channel (516) is capable of communicating the sealant (592) through the inlet opening (306) of the fitted cap (300) into the uniform gap (302), and the vent (309) is oriented to purge gas from the uniform gap (302). The fitted cap (300) is rotatable together with the shaft (510) to distribute the sealant (592) in the uniform gap (302) to form the shaped sealant shroud (590).

Claims

1. A system for applying a shaped sealant shroud to a portion of a fastener, the system comprising:

a fitted cap, comprising a wall and positionable over the portion of the fastener such that a uniform gap is formed between the wall and the portion of the fastener, wherein the fitted cap further comprises;

an inlet opening, fully penetrating the wall, such that the inlet opening is configured to be communicatively coupled with the uniform gap; and

a vent, fully penetrating the wall, such that the vent is configured to be communicatively coupled with the uniform gap, wherein the inlet opening and the vent are spaced apart from each other along the wall; and

a cap-manipulation tool, comprising a shaft, wherein;

the shaft has a longitudinal central axis and comprises a through, circumferentially closed, channel, configured to receive sealant and to communicate the sealant therethrough; and

the cap-manipulation tool is configured to couple to the fitted cap such that;

the through, circumferentially closed, channel of the shaft is capable of communicating the sealant through the inlet opening of the fitted cap into the uniform gap;

the vent is oriented to purge gas from the uniform gap as the sealant is communicated through the through, circumferentially closed, channel into the uniform gap; and

the fitted cap is rotatable together with the shaft about the longitudinal central axis of the shaft to distribute the sealant in the uniform gap to form the shaped sealant shroud around the portion of the fastener.

2. The system according to claim 1, wherein the fastener is configured for installation on a first member, such that the portion of the fastener extends from a base surface of the first member, and the fitted cap comprises a first cap end, configured to mount against the base surface.

3. The system according to claim 1, wherein a gap width of the uniform gap is within a predefined tolerance range for a shroud thickness of the shaped sealant shroud on the portion of the fastener.

4. The system according to claim 1, wherein:

the shaft comprises a first shaft end and a second shaft end, opposite the first shaft end, and extends longitudinally from the first shaft end to the second shaft end;

the cap-manipulation tool further comprises an interface bushing that has a passage therethrough; and

the interface bushing is configured to couple between the second shaft end and the fitted cap such that, with the fitted cap positioned over the portion of the fastener, the through, circumferentially closed, channel is communicatively coupled with the passage, the inlet opening, and the uniform gap.

5. The system according to claim 4, wherein:

the fitted cap comprises a tapered interface portion;

the interface bushing comprises a sidewall, having a sidewall taper angle relative to the longitudinal central axis; and

the sidewall of the interface bushing is configured to couple to the tapered interface portion of the fitted cap with an interference fit.

6. The system according to claim 5, wherein:

the tapered interface portion of the fitted cap has a cap taper angle relative to the longitudinal central axis and

the cap taper angle differs from the sidewall taper angle of the interface bushing by at least 10 degrees.

7. The system according to claim 4, wherein the interface bushing comprises a skirt, configured to couple to the second shaft end with an interference fit.

8. The system according to claim 1, wherein the cap-manipulation tool further comprises a handle, coupled to the shaft and movable to rotate the shaft about the longitudinal central axis.

9. The system according to claim 8, wherein:

the shaft comprises a first shaft end and a second shaft end, opposite the first shaft end, and extends between the first shaft end and the second shaft end and

the handle is longitudinally translatable between the first shaft end and the second shaft end to cause rotational motion of the shaft about the longitudinal central axis.

10. The system according to claim 9, wherein the handle is longitudinally non-concurrently translatable in two opposing axial directions between the first shaft end and the second shaft end such that the shaft is respectively non-concurrently rotatable in two opposing rotational directions about the longitudinal central axis.

11. A method for applying a shaped sealant shroud to a portion of a fastener, the method comprising steps of:

positioning a fitted cap, comprising a wall, over the portion of the fastener such that a uniform gap is formed between the wall of the fitted cap and the portion of the fastener, wherein the fitted cap further comprises;

an inlet opening, fully penetrating the wall, such that the inlet opening is configured to be communicatively coupled with the uniform gap; and

a vent, fully penetrating the wall, such that the vent is configured to be communicatively coupled with the uniform gap, wherein the inlet opening and the vent are spaced apart from each other along the wall;

coupling a cap-manipulation tool to the fitted cap, wherein the cap-manipulation tool comprises a shaft, and wherein the shaft comprises a through, circumferentially closed, channel, configured to be communicatively coupled with the inlet opening of the fitted cap;

supplying sealant into the through, circumferentially closed, channel of the shaft, through the inlet opening of the fitted cap, and into the uniform gap, wherein the vent is oriented to purge gas from the uniform gap as the sealant is communicated through the through, circumferentially closed, channel and into the uniform gap; and

rotating the shaft about a longitudinal central axis of the shaft, wherein the fitted cap rotates together with the shaft such that the sealant is distributed in the uniform gap to form the shaped sealant shroud around the portion of the fastener.

12. The method according to claim 11, wherein:

the fastener is installed on a first member such that the portion of the fastener extends from a base surface of the first member and

the method further comprises mounting a first cap end of the fitted cap against the base surface.

13. The method according to claim 11, wherein the step of positioning the fitted cap over the portion of the fastener comprises positioning the fitted cap such that a gap width of the uniform gap is within a predefined tolerance range for a shroud thickness of the shaped sealant shroud on the portion of the fastener.

14. The method according to claim 11, wherein:

the shaft extends longitudinally from a first shaft end to a second shaft end;

the method further comprises a step of coupling an interface bushing between the second shaft end and the fitted cap; and

the step of supplying the sealant into the through, circumferentially closed, channel through the inlet opening of the fitted cap and into the uniform gap further comprises supplying the sealant from the through, circumferentially closed, channel through a passage that extends through the interface bushing, through the inlet opening, and into the uniform gap.

15. The method according to claim 14, wherein:

the fitted cap comprises a tapered interface portion;

the interface bushing comprises a sidewall, having a sidewall taper angle relative to the longitudinal central axis; and

the step of coupling the interface bushing between the second shaft end of the shaft and the fitted cap comprises a step of coupling the sidewall of the interface bushing to the tapered interface portion of the fitted cap with an interference fit.

16. The method according to claim 15, wherein the step of coupling the sidewall of the interface bushing to the tapered interface portion of the fitted cap comprises coupling the sidewall, having the sidewall taper angle that differs by at least 10 degrees from a cap taper angle, defined by the tapered interface portion of the fitted cap relative to the longitudinal central axis.

17. The method according to claim 14, further comprising coupling a skirt of the interface bushing to the second shaft end of the shaft with an interference fit.

18. The method according to claim 11, wherein:

the cap-manipulation tool further comprises a handle, coupled to the shaft, and

the step of rotating the shaft about the longitudinal central axis of the shaft is accomplished by a step of moving the handle.

19. The method according to claim 18, wherein:

the shaft extends between a first shaft end and a second shaft end and

the step of rotating the shaft about the longitudinal central axis of the shaft is accomplished by a step of longitudinally translating the handle between the first shaft end and the second shaft end.

20. The method according to claim 19, wherein the step of longitudinally translating the handle between the first shaft end and the second shaft end comprises longitudinally non-concurrently translating the handle in two opposing axial directions between the first shaft end and the second shaft end such that the shaft respectively non-concurrently rotates in two opposing rotational directions about the longitudinal central axis.