Portable sealant dispense system

1. Field of Invention

The present disclosure relates generally to a nozzle for dispensing sealant on aircraft fasteners. More specifically, the present disclosure concerns nozzles adapted to enclose an exposed fastener head and meter an amount of sealant over the fastener head.

2. Description of Prior Art

Aircraft fuel tanks are typically assembled by fastening together sheets of metal or composite material. Fastening techniques include adhesive compounds, welding, and rivets. Riveting pierces the sheets being fastened thus creating a potential fluid leakage path along the rivet. To prevent leakage across the rivets, a sealant is generally applied along the interface between a fastener head and the exterior of the fuel tank. Referring now to FIG. 1A , a prior art example of a fastener 14 is shown attached to an upper fastened member 10 . An interface 17 defines the fastener 14 to upper fastened member 10 contact periphery. Shown in sectional view in FIG. 1B , the fastener 14 includes a rounded head 16 set atop the upper fastened member 10 . A shaft 18 depends from the head 16 through the upper fastened member 10 and into a lower fastened member 12 . FIG. 1C illustrates in a side sectional view sealant 20 having been applied over the fastener head 16 . The sealant 20 encompasses the interface 17 and extends past the interface 17 on the entire fastener 14 periphery.

FIGS. 2A through 2C illustrate a fastener 14 A that includes a dome 19 projecting upward from an elliptically shaped base assembly 15 . The base assembly 15 shown is mounted on the upper fastened member 10 with rivets 16 A. As shown in side sectional view in FIG. 2B , the interface between the fastener 14 A and upper fastened member 10 is defined by the outer periphery of the base assembly 15 adjacent the upper fastened member 10 . Thus, sealant 20 ( FIG. 2C ) shown applied atop the fastener 14 A extends along the outer periphery of the base assembly 15 , thereby encompassing the interface 17 A between the fastener 14 A and upper fastened member 10 .

Current techniques for applying sealant 20 to fasteners 14 , 14 A are typically manual such as brushing sealant onto the fastener or using a dispenser, with or without a metered supply of sealant 20 . These current techniques can have results that vary with personnel applying the sealant and between applications performed by the same individual. These methods are also time consuming and often lead to an excess amount of sealant applied to the particular fastener 14 , 14 A. Since an aircraft can include a multiplicity of fasteners, the additive effect of excess sealant can unnecessarily increase overall aircraft weight.

A system and method for dispensing a sealant over aircraft fasteners secured to a surface in the aircraft. The system includes a nozzle tip having a shroud configured for placement over the fasteners. Sealant is metered to the shroud via an orifice within the nozzle tip. The shroud is sized to leave a space between it and the fastener to control the amount of sealant applied to the fastener upper surface and along the interface between the fastener and aircraft surface. Pressurized fluid urges the sealant through the orifice.

Some of the features and benefits of the present invention having been stated, others will become apparent as the description proceeds when taken in conjunction with the accompanying drawings, in which:

FIGS. 1A and 2A are overhead views of prior art fastening members used in aircraft construction.

FIGS. 1B and 2B are respective side partial sectional views of the fastening members of FIGS. 1A and 2A .

FIGS. 1C and 2C are respective side sectional views of the fasteners of FIGS. 1B and 2B with applied sealant.

FIG. 3 is a side partially schematic view of a dispensing system for dispensing sealant to aircraft fasteners.

FIGS. 4A through 4F depict in perspective view various embodiments of nozzle tips for use with the dispenser of FIG. 3 .

FIG. 5A is a side perspective view of a dispenser and nozzle tip applying sealant to a fastener.

FIG. 5B is a frontal view of an opening of a nozzle tip having sealant.

FIGS. 6A and 7A illustrate overhead views of fasteners having sealant applied using a system described herein.

FIGS. 6B and 7B respectively are side sectional views of the fasteners with applied sealant of FIGS. 6A and 7A .

It will be understood the improvement described herein is not limited to the embodiments provided. On the contrary, the present disclosure is intended to cover all alternatives, modifications, and equivalents, as may be included within the spirit and scope of the improvement as defined by the appended claims.

The improvement(s) of the present disclosure will now be described more fully hereinafter with reference to the accompanying drawings in which disclosed embodiments are shown. The disclosed improvement(s) may, however, be embodied in many different forms and should not be construed as limited to the illustrated embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be through and complete, and will fully convey the scope of the disclosure to those skilled in the art. Like numbers refer to like elements throughout.

It is to be understood that the improvement(s) described herein is not limited to the exact details of construction, operation, exact materials, or embodiments shown and described, as modifications and equivalents will be apparent to one skilled in the art. In the drawings and specification, there have been disclosed illustrative embodiments and, although specific terms are employed, they are used in a generic and descriptive sense only and not for the purpose of limitation. Accordingly, applicants' improvements) is therefore to be limited only by the scope of the appended claims.

An example of a sealant dispensing system 30 is shown in a side partially schematic view in FIG. 3 . The sealant dispensing system 30 includes a pressurized fluid supply 32 operatively coupled with a controller 34 . Although the controller is shown attached or connected to the fluid supply 32 via a line 33 , the controller 34 may be integral with the pressurized fluid supply 32 . In one example, the pressurized fluid supply provides a pressurized gas, such as air or nitrogen, through fluid supply line 36 to a dispenser 38 . The dispenser 38 of FIG. 3 includes an activator switch 40 for selectively providing fluid communication to the dispenser 38 from the pressurized fluid source 32 . The dispenser 38 further includes an outer cylindrical housing 42 in which a supply of sealant (not shown) is stored. The sealant may be obtained in cylindrical cartridges, which are insertable into the housing 42 by removing an end cap 44 . An example of a suitable cartridge is a Semco cartridge which is available from PPG Industries, One PPG Place, Pittsburgh, Pa. 15272.

The dispensing system 30 of FIG. 3 further includes a nozzle tip 46 shown attached to a sealant tube at the end of the housing 42 opposite the end cap 44 . The nozzle tip 46 as illustrated includes an annular cylindrical housing 54 with an annular canopy 48 coaxially affixed on an end of the housing 54 . Also included with the nozzle tip 46 is a cylindrical nozzle inlet 56 that depends laterally from a side of the housing 54 and oblique to the housing 54 axis. The nozzle inlet 56 connects to a discharge end of the sealant tube opposite its connection to the housing 54 .

Examples of nozzle tips 46 suitable for use with the dispensing system 30 are provided in perspective views in FIGS. 4A through 4F . With reference now to FIG. 4A , an example of a nozzle tip 46 is provided in a perspective view and facing an open end of the canopy 48 A. In this example, the canopy 48 A outer periphery is octagonal. The canopy 48 A sides that are oblique to the nozzle inlet axis A X are elongated, thereby forming an elliptically-shaped periphery. The canopy 48 A projects forward from a canopy base 50 A, thereby defining cavity or an enclosed space 47 A within the canopy 48 A. The canopy base 50 A provides a barrier between the canopy 48 A opening and the nozzle inlet 56 . Applicator ports 52 A are shown formed through the canopy base 50 A, thereby providing fluid communication between the nozzle inlet 56 A and the space 47 A defined by the canopy 48 A. The applicator ports 52 A of FIG. 4A are arranged along a path, a portion of which runs adjacent to the canopy 48 A walls. A domed recess 53 A is shown formed in approximately the mid portion of the canopy base 50 A. In one example of use, the domed reservoir 53 A is adapted to receive the head portion of a fastener therein.

A perspective view of a nozzle tip 46 B is provided in FIG. 4B . In this example, the nozzle inlet 56 B is shown having threads 58 B circumscribing its outer surface. Also provided on the nozzle inlet 56 B is an orifice 60 B and sized for allowing sealant to enter into the nozzle tip 46 B from the dispenser 38 . Sizing of the orifice 60 B can be dependent upon the type of sealant to be used based on sealant properties as well as particular applications and operating conditions.

Referring now to FIG. 4C , an example of a nozzle tip 46 C is shown in a perspective view. The nozzle tip 46 C includes a cylindrical body 54 C having a nozzle inlet 56 C depending from a side of the body 54 C and angled oblique to the body 54 C axis. Coaxially with the body 54 C is an attached canopy 48 C circumscribing a recessed canopy base 50 C. The canopy 48 C outer walls extend away from the body 54 C to define a space 47 C within the canopy 48 C. Applicator ports 52 C are shown formed through the canopy base 50 C that allow for fluid communication between the inside of the body 54 C and the canopy space 47 C. An optional domed recess 53 C is shown formed in the mid portion of the canopy base 50 C.

An alternative embodiment of a nozzle tip 46 D is provided in a perspective view in FIG. 4D . In this embodiment, the canopy 48 D shape is substantially the same as the housing 54 D. Thus, the canopy 48 D outer periphery is circular rather than the pseudo-elliptical shape of FIG. 4C . The canopy base 50 D disposed within the walls of the canopy 48 D is recessed inwards towards the housing 54 D, thereby defining a space 47 D circumscribed by the canopy 48 D and bounded by the canopy base 50 D. In this embodiment, the applicator ports 52 D are shown formed within a recess 53 D in the mid portion of the canopy base 50 D. In this example, sealant flowing from the ports 52 D flows first onto the fastener head or mid-portion then into the space 47 D defined by the canopy 48 D and canopy base 50 D. This differs from the operation of the nozzle tip 46 C of FIG. 4C , wherein sealant flowing through the applicator ports 52 C is directed at or around an interface between a fastener and a fastened member, and then the sealant flows radially inward to fill the space 47 C defined by the canopy 48 C.

Another example of a nozzle tip 46 E is shown in a perspective view in FIG. 4E . In this example, the canopy 48 E includes walls that are extensions of the housing 54 E. Also in this example are fins 49 E radially aligned with the housing 54 E axis and disposed at various points around the circumference of the nozzle tip 46 E opening. A canopy base is not included in this example, but instead sealant can flow freely from the inlet 56 E through the body 54 E and out of the nozzle tip 46 E opening. The fins 49 E may be configured for placement on the outer periphery of a fastener, thereby aligning the nozzle tip 46 E so a uniform amount of sealant may be placed over the fastener.

In FIG. 4F , an example of a nozzle tip 46 F is shown in a perspective and partially exploded view. In this example, an annular housing 54 F has a cylindrical nozzle tip inlet 56 F attached to its side and at an angle to its axis A X . An annular applicator assembly 51 F is shown adapted for coupling with an open side of the body 54 F. On one side of the assembly 51 F, a ring-like insert 55 F depends inward for insertion into the housing 54 F. Slots 57 F are shown provided on the insert 55 F outer surface at locations around its circumference. A groove 59 F circumscribes the insert 55 F and intersecting the slots 57 F. When inserted within the housing 54 F, the groove 59 F registers with an exit orifice 61 F shown provided through the housing and allowing fluid communication between the housing and the nozzle inlet 56 F. Thus, sealant flowing through the nozzle inlet 56 F and exiting the exit orifice 61 F enters the groove 59 F, makes its way to the slots 57 F and into the confines of the housing 54 F. The assembly 51 F of FIG. 4F is rotatable with respect to the body 54 F. Thus rotating the assembly 51 F can avoid an interference between the dispenser 38 and an immovable object, if the fastener head requires a particular nozzle tip 46 F orientation.

A canopy 48 F having a square-like outer periphery is provided on the side of the applicator assembly 51 F opposite the insert 55 F. Provided within the enclosure formed by the canopy 48 F is a canopy ring 64 F circumscribing the housing 54 F axis A X . Ring supports 66 F extend from the canopy ring 64 F outer circumference and attach within the inner surface of the canopy 48 F. In one example of use, the canopy ring 64 F is configured for placement on a fastener head when applying sealant onto an aircraft fastener. A circular rear plug 68 F is shown proximate the side of the housing 54 F opposite where it receives the applicator assembly 51 F. Attaching the rear plug 68 F thereby forms an enclosed space within the housing 54 F to force sealant therein out through the exit path formed by the canopy 48 F for sealing the interface around an aircraft fastener and fastened member.

In FIG. 5A , a side perspective view of the dispenser 38 and nozzle tip 46 of FIG. 3 is shown applying sealant to a fastener coupled to an upper fastened member 10 . FIG. 5B provides a front view of sealant being urged outward from the applicator ports 52 of a nozzle tip 46 . As described above, placing the nozzle tip 46 over a fastener encloses the space adjacent in covering the interface between an aircraft fastener and the fastened member to which it is coupled. Selectively applying the pressurized fluid to the supply of sealant forces the sealant from the dispenser and into the nozzle tip 46 . Using the same nozzle tip to apply sealant to multiple fasteners controls the amount of sealant applied to each fastener. Filling with sealant the space around the interface dispenses a sufficient amount of sealant for sealing around the fastener and avoids application of excess sealant, thereby reducing total mass of applied sealant. Optionally, the controller 34 ( FIG. 3 ) can be configured to selectively apply an amount of pressurized fluid so the amount of sealant urged from the dispenser 38 fills the space 47 in the canopy 48 .

The nozzle tip 46 and its components may be foamed from the same or different materials. Example materials include elastomeric compounds, metals, composites, plastics, synthetic plastics, semi-synthetic plastics, polyamides, polymers, such as but not limited to thermoplastic polymers, polycarbonates, polystyrene, polyvinylchloride, polyethylene (low and high density), polypropylene, polyfluoroethylene, polytetrafluoroethylene, polyethylene terephthalate, combinations thereof and the like. In one example, an elastomeric seal (not shown) is provided on the forward facing end of the shroud 48 for sealing around the shroud 48 to prevent sealant from leaking within the space 47 .

FIG. 6A is an overhead view of an example of a fastener 14 having sealant 70 applied using the technique and system described herein. FIG. 6B is a side sectional view depicting a bead of sealant 70 applied over the fastener of FIG. 6A . The sealant 70 in FIG. 6B covers the interface 17 between the fastener head 16 and upper fastened member 10 . This prevents a leakage of fluid from underneath the lower fastened member 12 up the fastener 14 and past the interface 17 . Shown in an overhead view in FIG. 7A is an alternate fastener 14 A having a base 15 and an upwardly projecting dome portion 19 . Sealant 70 is shown applied on its base 15 and along its outer periphery. FIG. 7B illustrates the fastener 14 A of FIG. 7A in a side sectional view and depicts the dome portion 19 and upper portion of the base 15 are substantially free of applied sealant. Instead, the sealant 70 is applied primarily along the interface 17 A. As noted above, eliminating the application of excess sealant has a significant advantage with regard to weight savings.

The method described herein clearly provides a significant time savings for dispensing sealant to fasteners. In one example of use, using the system for and method of application described, herein, the time to apply sealant to a series of fasteners was reduced by almost 75% over current methods. In another example the application time was reduced by about 82%. Moreover, use the present system and method provided weight reductions of 34% and 36% over current methods.

The present system and method described herein, therefore, is well adapted to carry out the objects and attain the ends and advantages mentioned, as well as others inherent therein. While a presently preferred embodiment has been given for purposes of disclosure, numerous changes exist in the details of procedures for accomplishing the desired results. The system and method described herein can be used in applying a flowable substance in any application; such as but not limited to vessel fasteners, vehicle fasteners, industrial fasteners, and along any interface. These and other similar modifications will readily suggest themselves to those skilled in the art, and are intended to be encompassed within the spirit of the present disclosure and the scope of the appended claims.