HK1203225B - Nut plate seal caps - Google Patents

Description

Nut plate sealing cap

Cross Reference to Related Applications

In accordance with 35u.s.c. § 119(e), the present application claims priority from U.S. provisional patent application No.61/622874 entitled "nutplate" entitled "provisional patent application No.61/622874, filed on day 2012, 4/11, which is incorporated herein by reference in its entirety.

Technical Field

The present invention relates to sealant materials, in particular to premade caps for sealing mechanical fasteners, methods for making such premade caps, and methods for applying such premade caps to substrates. The invention also relates to a driver for applying a sealant material to a substrate.

Background

Dispensing systems for dispensing curable sealants are well known in the art. There are a variety of methods for applying sealant to fasteners using caps. These methods include applying the sealant and then forming it over the fastener by a cap, or injecting the sealant into a cap surrounding the fastener. These methods require precise metering of the sealant around the fastener prior to placing the cap around the sealant, or into the cap prior to placing the cap and sealant over the fastener. These methods are costly and impractical. Moreover, these methods do not provide consistent results.

A preformed sealant cap filled with uncured sealant just prior to application to the fastener is also inefficient. This additional step of filling the cap with uncured sealant would make it cumbersome to apply the sealant to the fastener. Common practice involves applying sealant to multiple fasteners at once. The additional step of filling the cap complicates the application and increases the length of time required to apply the sealant to the fasteners throughout the substrate. The sealant cures within a fixed time after dispensing and complicates dispensing the sealant prior to application to the fastener.

Moreover, many manufacturers manually seal the nut plate fasteners by extruding and applying a sealant to the fasteners with a tool. However, this is a difficult and time consuming process, as many fasteners are placed in difficult to access locations, thereby making it technically difficult to access and seal the fasteners. In addition, it is often difficult to control the thickness of the sealant applied to the fastener.

Finally, fasteners are often manufactured in series, with the fasteners in each series having a particular base size and providing a range of shank lengths. Thus, pre-fabricated sealant caps are typically manufactured for each series of individual stem lengths. This increases the manufacturing cost.

There is therefore a need for a sealant that addresses the inefficiencies and complexities of existing materials.

Disclosure of Invention

In certain embodiments, the present invention relates to a cap for sealing a mechanical fastener, the cap comprising: a housing having an outer surface and an inner surface, the inner surface defining a cavity; an opening extending through the housing between the inner surface and the outer surface; and a sealant at least partially filling the cavity.

In certain other embodiments, the present invention relates to a cap assembly for sealing a mechanical fastener, the cap assembly comprising: a housing having an outer surface and an inner surface, the inner surface defining a cavity; an opening extending through the housing between the inner surface and the outer surface; a sealant at least partially filling the cavity; and a tube extending through the opening and configured to fit over the shaft of the mechanical fastener, wherein the housing is slidably movable along an axis of the tube.

In certain other embodiments, the present invention relates to a sealant cap pack comprising a holder and a plurality of cap assemblies releasably mounted on the holder, wherein each cap assembly comprises: a housing having an outer surface and an inner surface, the inner surface defining a cavity; an opening extending through the housing between the inner surface and the outer surface; a sealant at least partially filling the cavity; and a tube extending through the opening, wherein the tube is releasably secured to the retainer.

In certain other embodiments, the present invention relates to a method of installing a cap onto a mechanical fastener, wherein the cap comprises: a housing having an outer surface and an inner surface, the inner surface defining a cavity; an opening extending through the housing between the inner surface and the outer surface; a sealant at least partially filling the cavity; and a tube extending through the opening and configured to fit over the shaft of the mechanical fastener; the method comprises the following steps: inserting the shaft of the mechanical fastener into the tube; and sliding the housing along the axis of the tube from an initial position to an installed position in which the sealant contacts a portion of a mechanical fastener and a substrate into which the mechanical fastener is fastened.

In certain other embodiments, the present invention relates to a driver for mounting a cap assembly to a mechanical fastener, wherein the cap assembly comprises: a housing having an outer surface and an inner surface, the inner surface defining a cavity; an opening extending through the housing between the inner surface and the outer surface; a sealant at least partially filling the cavity; and a tube extending through the opening and configured to fit over the shaft of the mechanical fastener; wherein the housing is slidably movable along an axis of the elongated tube, the tool comprising: a clip constructed and arranged to releasably engage the tube; and a sleeve constructed and arranged to move the housing along the axis of the tube from an initial position to an installed position in which the sealant contacts a portion of a mechanical fastener and a portion of a base to which the mechanical fastener is fastened.

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate some non-limiting embodiments of the invention and, together with the description, serve to explain the invention.

Drawings

FIG. 1 illustrates a top isometric view of an embodiment of a cap for sealing a mechanical fastener;

FIG. 2 shows a bottom isometric view of the cap shown in FIG. 1;

FIG. 3 is a top view of the cap shown in FIG. 1;

FIG. 4 is a side cross-sectional view of the cap shown in FIG. 1;

FIG. 5 is an isometric view of the cap shown in FIG. 1, shown in combination with a tube extending through an opening in the cap configured to engage a stem of a mechanical fastener;

FIG. 6 is a top view of the cap and tube combination shown in FIG. 4;

FIG. 7 is a side cross-sectional view of the cap and tube combination shown in FIG. 5;

FIG. 8 is a side cross-sectional view of the cap and tube combination shown in FIG. 5, showing the tube installed on the mechanical fastener;

FIG. 9 is a side cross-sectional view of the cap and tube combination shown in FIG. 5, illustrating the cap engaged with the mechanical fastener;

FIG. 10 is a side cross-sectional view of the cap and tube combination shown in FIG. 5, showing the tube removed and the cap engaged with the mechanical fastener;

FIG. 11 is an exploded view of the assembly fixture in combination with a plurality of cap assemblies;

FIG. 12 is an exploded view of the retainer in combination with a plurality of cap assemblies;

FIG. 13 is an isometric view of a tool shown in an initial position for mounting the cap of the cap assembly shown in FIG. 5 to a fastener;

FIG. 14 is an isometric view of the tool shown in FIG. 13, shown in an intermediate position; and

fig. 15 is an isometric view of the tool shown in fig. 13, shown in an installed position.

Detailed Description

Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.

For the purposes of this description, it is to be understood that the invention may assume various alternative variations and step sequences, except where expressly specified to the contrary. Moreover, other than in any operating examples, or where otherwise indicated, all numbers expressing, for example, quantities of ingredients used in the specification and claims are to be understood as being modified in all instances by the term "about". Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and attached claims are approximations that may vary depending upon the desired properties to be obtained by the present invention. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard variation found in their respective testing measurements.

Also, it should be understood that any numerical range recited herein is intended to include all sub-ranges subsumed therein. For example, a range of "1 to 10" is intended to include all sub-ranges between (and including) the recited minimum value of 1 and the recited maximum value of 10, that is, having a minimum value equal to or greater than 1 and a maximum value of equal to or less than 10.

The term "sealant" as used herein refers to a composition that, when applied to an aperture (e.g., a joint or void formed by an interface between two components), has the following capabilities: resistant to atmospheric conditions (e.g., moisture and temperature) and at least partially block the transmission of materials (e.g., water, fuel, and/or other liquids and gases) that might otherwise be present in the pores. Thus, a sealant is often applied to the peripheral edge surfaces of component parts in order to impede the transport of substances to or from the part. Sealants typically have adhesive properties, but are not simple adhesives that do not have the barrier properties of sealants.

Fig. 1-4 illustrate a non-limiting embodiment of a cap 10 for sealing a mechanical fastener 200. Each cap 10 has a housing 12, the housing 12 being configured to engage a base 210 of a fastener. Each housing 12 has an inner surface 16 and an outer surface 14. The inner surface 16 of the housing defines a cavity 18. As shown in fig. 3 and 6, a first quantity of encapsulant 13 is disposed in the cavity 18, and in certain embodiments, the encapsulant 13 may be at least partially uncured. The housing 12 is made of any rigid material, including: a second amount of sealant that is at least partially hardened; a plastic comprising a hydrophobic polymer; and so on. In certain embodiments, the housing and the sealant comprise the same components.

The term "at least partially unhardened" is meant to include the entire hardness range from completely liquid to a point at least slightly gelled such that the first amount of sealant is able to conform to the surface of the substrate. Conversely, the term "at least partially hardened" is meant to include the entire range of hardness from fully cured to at least slightly gelled such that the second amount of sealant can be manually or mechanically manipulated into a point for application to the substrate. It is therefore contemplated that a portion of the sealant can be hardened or unhardened such that the sealant is not consistent throughout the amount of sealant. For example, the sealant need not be cured at the same time, and there can be the possibility of uncured sealant packages in an almost completely cured sealant and cured sealant packages in an almost completely uncured sealant.

The hardening or curing time of the sealant depends on the pot life of the sealant components and can vary widely from a few minutes to a few hours. In a further non-limiting example, the second quantity of sealant can be thermally conditioned to prevent it from fully curing prior to disposing the first quantity of sealant in the cavity.

As shown in fig. 1-4, an opening 19 extends through the housing 12. In the non-limiting embodiment shown in fig. 5-7, a tube 20 having a first end 22 and a second end 24 extends through the opening 19. As shown in fig. 8 and 9, the tube 20 may be provided as a sleeve over the shank 210 of the fastener 200. In certain embodiments, the housing 12 may be slidably movable along the axis a of the tube 20. The tube 20 may be made of any rigid material compatible with the first quantity of sealant 13, including but not limited to cardboard, plastic, and the like. In certain embodiments, the inner surface (not shown) of the tube 20 may be coated with a material compatible with the first quantity of sealant 13. The term "compatible" as used herein with reference to the sealant means that the materials do not adversely affect the sealant properties of the sealant.

Manufacturing a non-limiting embodiment of the cap 10 of the present invention includes assembling the cap assembly 100 by removing a top portion of the housing 10 to form an opening 19, the opening 19 extending between the inner and outer surfaces 14, 16 of the housing 10 (fig. 1-4). Those skilled in the art know a variety of ways to remove the top portion of the housing 10 to expose the opening 19.

In a non-limiting embodiment of manufacturing the cap 10, the tube 20 may be inserted through the opening 19 (fig. 5-7). Alternatively, as shown in FIG. 11, in a non-limiting embodiment of the assembly cap assembly 100, the first end 22 of the tube is positioned on the assembly fixture 310 such that the housing 10 is positioned over the surface 312 of the fixture and such that the cavity 18 of the housing 10 is positioned to receive the first quantity of sealant 13.

In certain embodiments of the present invention, a first quantity of encapsulant 13 is disposed in the cavity 18. In one non-limiting embodiment, a sufficient first amount of sealant 13 can be used to fill the cavity 18 to just above the surface of the cavity 18. In a non-limiting embodiment, the first quantity of sealant 13 remains at least partially uncured by thermally conditioning it to a temperature sufficiently below its curing temperature (so as to at least partially delay curing of the sealant). Release paper or other similar material known to those skilled in the art can be reapplied over the first quantity of sealant. Such packaging at least partially prevents the formation of moisture when the sealant is thermally conditioned during storage and shipping and when the temperature of the sealant is elevated prior to application. The combination of the preformed first quantity of sealant 13 disposed in the cavity 18 of the housing 12 is thermally conditioned until applied to the fastener and/or substrate. The term "pre-form" refers to the dispensing and packaging of the quantity of sealant so that the sealant can be stored and transported before it is applied to a substrate.

The term "thermally conditioning" refers to reducing and/or maintaining the temperature of the first quantity of encapsulant 13 at a temperature that will delay hardening by at least partially delaying the curing process. The temperature can be lowered to effectively delay the curing process. In one non-limiting embodiment, the length of time for the curing process to reach completion can be inversely related to the temperature, such that the lower the temperature, the greater the delay in the curing process and the rate of hardening. In one non-limiting embodiment, the reduction and/or maintenance of the temperature can last from a point in time when the first quantity of sealant 13 is manufactured and disposed within the cavity 18 of the housing 10 to a point in time when the first quantity of sealant 13 is ready to be applied to a substrate. Thus, cooling may be used during storage and transportation of the first quantity of sealant 13, such as transporting the first quantity of sealant 13 under refrigerated conditions or in dry ice.

The temperature at which the above-described curing process is delayed can vary widely and depends on the shelf life of the first quantity of sealant 13. The pot life of the sealant relative to temperature will vary due to the sealant composition. In one non-limiting example, the shelf life of the sealant can be 21 days at-40 ℃. The shelf life can be extended by lowering the temperature. In one non-limiting embodiment, the sealant can be maintained at a temperature between-100 ℃ and-25 ℃, inclusive, to delay hardening. In another non-limiting embodiment, the sealant can be maintained at a maximum temperature of-75 ℃. In another non-limiting embodiment, the sealant can be maintained at a minimum temperature of-55 ℃. In another non-limiting embodiment, the sealant can be maintained at-45 ℃. The choice of sealant is not critical and a variety of materials known in the art can be used.

The particular choice of sealant will generally depend on a number of factors, such as the type of substrate and the intended end use. Non-limiting examples of commercially available sealantsExamples include those produced by prcdeso international, IncAndand produced by ACTech (PBTBrands, Inc., Hartford Conn.)Andin addition, the method of prefabricating an at least partially unhardened material can be used for other components, such as adhesives, coatings, etc.

In the above non-limiting embodiment, the first amount of sealant 13 can be cured or hardened by heating. In another non-limiting embodiment, the first quantity of encapsulant 13 can be cured or hardened by oxidation. In this embodiment, oxidation of the first quantity of encapsulant 13 can be delayed by limiting exposure of the encapsulant to air so that the encapsulant remains locally uncured.

The term "prevent" refers to limiting, hindering, slowing, or interfering with a particular reaction or function. This can be accomplished in a number of ways, such as controlling the environment to which the encapsulant is exposed. In the case of oxidation, preventing refers to limiting, retarding, slowing, or interfering with the oxidation of the sealant. In a non-limiting example, oxidation is at least partially prevented by limiting the exposure of the sealant to air or ambient environmental conditions. In the case of moisture, preventing refers to restricting, retarding, slowing, or interfering with the presence of moisture onto the encapsulant. Non-limiting examples include at least partially preventing moisture by limiting condensation on the encapsulant surface.

Alternatively, in certain embodiments of the present invention, as shown in FIG. 11, after the first quantity of sealant 13 is disposed in the cavity 18 of the housing 12, a first tube support 314 including a plurality of nozzles 318 is disposed over the cap assembly 100. Each nozzle 318 is substantially aligned with one of the tubes 20 located on the mounting fixture 310 and is configured for insertion into the second end 24 of the respective tube. In certain embodiments, the nozzle 318 is inserted into the second end 24 of the tube, and optionally, the base 320 is disposed above the first tube support 314. In certain embodiments, the first tube support 314 is secured to the base 320.

Alternatively, in certain embodiments of the present invention, as shown in fig. 12, after the nozzle 318 is inserted into the second end 24 of the tube and the optional base 320 is disposed thereon, the base 320 is inverted. In certain embodiments, as shown in fig. 12, nozzle 318 holds housing 12 with a first quantity of sealant 13 above surface 316 of first tube support 314 at a distance such that the first quantity of sealant 13 does not contact surface 316 of the first tube support, thereby preventing the first quantity of sealant 13 from being sucked out of housing 12 (picking).

Alternatively, in certain embodiments, as shown in FIG. 12, a second tube support 324 including a plurality of apertures 328 is disposed over the cap assembly 100. Each aperture 328 is substantially aligned with one of the cap assemblies 100 located on the first tube support 314 and is configured for insertion of the first end 22 of a respective tube 20. In certain embodiments, a cap 330 is selectively disposed over the second tube support 324.

In certain non-limiting embodiments, the housing 12 may include a partially hardened sealant. In certain non-limiting embodiments, the housing 12 may be manufactured by compressing a second quantity of sealant to a predetermined thickness that forms the housing 12, the housing having a cavity 18, the first quantity of sealant 13 being disposed in the cavity 18. The second amount of sealant can remain at least partially hardened by thermally conditioning it. The housing 12 can be formed by any means known in the art, such as by using injection-fill molding, stamping, using male and female molds, and the like, at atmospheric, sub-atmospheric, or super-atmospheric pressures. Those skilled in the art will appreciate the various ways to form the concave shell into a variety of shapes and sizes to suit a particular application. An exemplary method of forming the outer shell is described in U.S. patent No.7438974, filed on date 2002, 9/26, 7438974, which is incorporated herein by reference.

In certain non-limiting embodiments, the sealant cap pack 500 includes a retainer 300 and a plurality of cap assemblies 100 releasably mounted on the retainer. The holder 300 is manufactured from a material having thermal properties that reduce the potential for condensation. While moisture can collect on the sealant, it can become trapped between the substrate and the sealant during application, thereby adversely affecting the performance of the sealant. A non-limiting embodiment of the sealant cap package 500 is shown in fig. 12. Each cap assembly 100 includes: a housing 12, the housing 12 having an outer surface 14 and an inner surface 16, the inner surface 16 defining a cavity 18; an opening 19, the opening 19 extending through the housing 12 between the inner surface 16 and the outer surface 14; a first quantity of sealant 13, the sealant 13 at least partially filling the cavity 18; and a tube 20, the tube 20 extending through the opening 19 and configured to be fitted over the shaft 210 of the mechanical fastener 200, wherein the housing 20 is slidably movable along an axis a of the tube 20. A plurality of cap assemblies may be releasably mounted on the first tube support 314, the first tube support 314 including a plurality of nozzles 318 projecting from a surface 316 thereof. The nozzle is configured for insertion into the second end 24 of the tube and may have a height above the surface 316 of the first tube support sufficient to raise the housing 12 containing the first quantity of sealant 13 to a distance above the surface 316 of the first support 314 such that the first quantity of sealant 12 does not contact the surface 316, thereby preventing the first quantity of sealant 13 from being drawn out of the housing 12. The number of nozzles 318 can vary depending on the number of cap assemblies 100 desired, the size of the mechanism used to dispense the first quantity of sealant 13 into the cavity 18, and the like. In certain embodiments, the first tube support 314 may be fixed or disposed in the base 320. A second tube support 324 including a plurality of apertures 328 may be positioned over the cap assembly 100. Each aperture 328 is provided for insertion of the first end 22 of the tube and may stabilize the cap assembly 100 in the retainer 300, for example, for stability during storage and transportation. In certain embodiments, the cap 330 is positioned over the second tube support 324.

Fig. 8-10 illustrate a non-limiting embodiment of a method for applying sealant to a fastener and/or matrix 230, including obtaining a preformed first quantity of sealant 13 at a temperature sufficient to at least partially harden the sealant, and contacting the sealant 13 with the matrix 230. Such temperatures can include thermally conditioning the sealant to gradually increase the temperature, or to bring the sealant to ambient temperature (20 ℃). In another non-limiting embodiment, the method of applying the sealant includes obtaining a preformed first quantity of sealant 13 under conditions sufficient to delay oxidation, and exposing it to air sufficient to oxidize the first quantity of sealant 13 to an at least partially hardened state.

There are several examples of fasteners, such as fasteners having convex, arcuate, or flat surfaces that utilize a sealant. Fig. 8-10 illustrate an example of a fastener 200 sealed using the cap assembly 100. The carrier 230 is fastened by fasteners 200 (fig. 8). Tube 20 is inserted over shank 210 of fastener 200 (fig. 8). The housing 12 moves along the axis a of the tube from an initial position (fig. 8) to an installed position in which the first quantity of sealant 13 contacts a portion of the mechanical fastener 200 and the matrix 230 in which the mechanical fastener is fastened (fig. 9). The tube 20 is removed from the opening 19 of the housing 12 so that the fastener 200 is at least partially coated with the first quantity of sealant 13 (fig. 10). The downward pressing motion (fig. 9) and removal of the tube 20 (fig. 20) causes a portion of the first quantity of sealant 13 to move so as to squeeze out a smaller portion of the sealant at the interface between the housing 12 and the matrix 230 (fig. 9, 10), at the interface between the housing 12 and the tube 20 (fig. 9), and/or at the interface between the housing 12 and the fastener 210 (fig. 10). Such an excess portion ensures a tight seal between the housing 12 and the matrix 230. The excess can be left entirely or even out to provide a smooth transition between the first quantity of sealant 13 and the carrier 230. The first (and optionally second) quantity of sealant 13 can be subjected to a temperature sufficient to at least partially harden the first quantity of sealant 13 when the sealant 13 is applied to the fastener 200 and the matrix 230.

In certain embodiments (such as the embodiment shown in fig. 13-15), a driver 400 for mounting the cap assembly 100 on the mechanical fastener 200 is disclosed. Driver 400 has a distal end 402 and a proximal end 404, the distal end 402 and proximal end 404 being connected by a cylindrical rod 410. The distal end 402 of the driver 400 includes a generally annular sleeve 406 and the proximal end 404 of the driver 400 includes a docking end 408, the docking end 408 configured to be engaged by the heel or thumb of an operator's hand. In one embodiment, the distal sleeve 406 and the proximal interface end 408 do not move relative to each other and may be fabricated from a single piece of material.

As also shown in fig. 13-15, driver 400 further includes a clip 420, which clip 420 includes a slightly tapered cylindrical split sleeve whose inner surface is capable of gripping and holding tube 20 of cap assembly 100. The clip 420 is connected to a retractor 430 having a cylindrical rod 432 that is coaxially mounted around the cylindrical rod 410 of the driver 400. Retractor 430 has two opposing finger gripping extensions 434 extending from its cylindrical shaft 432. Retractor 430 is coupled to clip 420 by a pin 436 or other mechanical fastener secured to proximal end 424 of clip 420.

As also shown in fig. 13-15, the cylindrical rod 410 of the driver 400 includes a longitudinal slot 425 through which a pin 436 connecting the retractor 430 with the clip 420 can extend. As retractor 430 is pulled from distal end 402 toward proximal end 404 of driver 400, pin 436 moves within longitudinal slot 425 of cylindrical rod 410 of driver 400 (fig. 13). With this arrangement, as the retractor 430 moves from the distal end 402 toward the proximal end 404 of the driver 400, it pulls the clip 420 axially within the sleeve 406. In some embodiments, the retractor 430 may be spring biased toward the distal end 402 of the driver 400, and the operator can pull the retractor 430 and the clip 420 away from the distal end 402 of the driver 400 against the force of the biasing spring (not shown) while pressing with the palm or thumb on the abutment end 408 of the driver 400 to keep the distal end 402 of the driver in contact with the housing 12 of the cap 10 as the tube 20 is retracted through the clip 420. The distal end of the sleeve 406 provides a contact surface for engaging and urging the housing 12 of the cap assembly (not shown) to its installed position relative to the fastener (not shown). The slightly tapered cylindrical outer surface of clip 420 in combination with at least one axial slot 425 through the sidewall of clip 420 provides an open position for first clamping tube 20 as clip 420 is moved distally relative to driver 400 (fig. 15). As the clip 420 moves toward the proximal end 404 of the driver 400, its outer surface engages the inner diameter of the cylindrical middle portion of the driver 400 and causes the split portions of the clip 420 to move radially inward to more tightly grip the tube 20 (FIGS. 13, 14). The inner surface of the clamp 420 may include serrations or other features that assist in gripping and securing the tube during operation.

The components of the driver 400 may be fabricated from any suitable material, such as metal, plastic, etc.

Other embodiments of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the invention being indicated by the following claims.

Claims (17)

1. A cap assembly for sealing a mechanical fastener comprising:

a housing having an outer surface and an inner surface, the inner surface defining a cavity;

an opening extending through the housing between the inner surface and the outer surface;

a sealant at least partially filling the cavity; and

a tube extending through the opening and configured to fit over the shaft of the mechanical fastener, wherein the housing is slidably movable along an axis of the tube.

2. The cap assembly of claim 1, wherein: the housing includes an at least partially hardened sealant.

3. The cap assembly of claim 1, wherein: the sealant is at least partially uncured.

4. The cap assembly of claim 1, wherein: the tube can be removed from the opening.

5. A sealant cap comprising:

a holder; and

a plurality of cap assemblies releasably mounted on the holder, wherein each cap assembly comprises:

a housing having an outer surface and an inner surface, the inner surface defining a cavity;

an opening extending through the housing between the inner surface and the outer surface;

a sealant at least partially filling the cavity; and

a tube extending through the opening, wherein the tube is releasably secured to the retainer.

6. The sealant cap pack according to claim 5, wherein: the holder includes a base including a plurality of nozzles, each nozzle being configured to engage the first end of one of the tubes.

7. The sealant cap pack according to claim 6, wherein: the housing is supported above a surface of the base.

8. The sealant cap pack according to claim 6, further comprising: an upper tube support comprising a plurality of apertures, each aperture configured to engage the second end of each tube, wherein the plurality of apertures are substantially aligned with the plurality of nozzles.

9. The sealant cap pack according to claim 5, further comprising: an upper tube support including a plurality of apertures, each aperture configured to engage the second end of each tube.

10. The sealant cap pack according to claim 5, further comprising: a cap positioned over the second end of each tube.

11. A method of installing a cap onto a mechanical fastener, wherein the cap comprises: a housing having an outer surface and an inner surface, the inner surface defining a cavity; an opening extending through the housing between the inner surface and the outer surface; a sealant at least partially filling the cavity; and a tube extending through the opening and configured to fit over the shaft of the mechanical fastener; the method comprises the following steps:

inserting the shaft of the mechanical fastener into the tube; and

the housing is slid along the axis of the tube from an initial position to an installed position in which the sealant contacts a portion of the base and a mechanical fastener secured into the base.

12. The method of claim 11, further comprising: the tube is removed from the opening after the housing is in the installed position.

13. The method of claim 11, wherein: the housing includes an at least partially hardened sealant.

14. The method of claim 11, wherein: the sealant is at least partially uncured.

15. A driver for mounting a sealant cap assembly to a mechanical fastener, wherein the sealant cap assembly comprises: a housing having an outer surface and an inner surface, the inner surface defining a cavity; an opening extending through the housing between the inner surface and the outer surface; a sealant at least partially filling the cavity; and a tube extending through the opening and configured to fit over the shaft of the mechanical fastener; wherein the housing is slidably movable along an axis of the elongated tube, the driver comprising:

a clip constructed and arranged to releasably engage a tube; and

a sleeve constructed and arranged to move the housing along the axis of the tube from an initial position to an installed position in which the sealant contacts a portion of a mechanical fastener and a portion of a base to which the mechanical fastener is fastened.

16. The driver of claim 15, wherein: the clip is axially movable relative to the sleeve.

17. The driver of claim 15, wherein: a sleeve at least partially surrounds the clip.