Fabrication and installation of preformed dielectric inserts for lightning strike protection

1. A fabrication method for providing a relatively smooth surface, the smooth surface associated with lightning strike protection for composite materials joined with fasteners recessed below the smooth surface, said method comprising:

providing a preformed dielectric insert having a backing material removably coupled to a top surface of the preformed dielectric insert;

coating at least one of a head of the recessed fastener and a bottom surface of the preformed dielectric insert with an adhesive, wherein the preformed dielectric insert is fabricated from at least two dielectric materials, wherein at least one of the at least two dielectric materials is an elastomer;

positioning the removable backing material on the smooth surface such that the preformed dielectric insert is inserted into a recess defined above the head of the recessed fastener, such that a portion of the adhesive is dispersed from the at least one of the head of the recessed fastener and the bottom surface of the preformed dielectric insert onto a side surface of the preformed dielectric insert and onto a wall at least partially defining the recess; and

removing, without using a blade, any excess adhesive from the surface area of the composite material and a top surface of the insert.

2. A fabrication method according to claim 1 further comprising:

selecting preformed dielectric inserts based on dimensions of the insert and dimensions of the recess into which the insert is to be placed, and

inspecting the surfaces of the dielectric insert for structural inconsistencies.

3. A fabrication method according to claim 1 wherein selecting preformed dielectric inserts comprises utilizing at least one of a color code on the removable backing material and color coded preformed dielectric inserts to identify the preformed dielectric insert dimensions.

4. A fabrication method according to claim 1 wherein positioning a preformed dielectric insert further comprises applying pressure to the dielectric insert, such that an amount of the adhesive is forced out of the recesses, thereby causing the adhesive to fill in disparities between the dielectric insert and the recess.

5. A fabrication method according to claim 1 further comprising:

injecting an uncured dielectric material into a mold;

curing the dielectric material; and

removing the cured dielectric material from the mold.

6. A fabrication method according to claim 5 wherein injecting an uncured dielectric material into a mold comprises injecting at least one of a ceramic, a thermosetting material, and a thermoplastic material into the mold.

7. A fabrication method according to claim 5 further comprising inspecting the cured dielectric material for structural inconsistencies and dimensional requirements before installation.

8. A fabrication method according to claim 1 wherein removing any excess adhesive comprises wiping the surface area of the composite material and an exposed surface of the dielectric insert before the adhesive dries.

9. A fabrication method according to claim 1 wherein coating at least one of a head of the fastener and a preformed dielectric insert with an adhesive comprises applying at least one of a thermoset adhesive, a thermoplastic elastomer adhesive, and a pressure sensitive adhesive.

10. A fabrication method according to claim 1 further comprising fabricating a dielectric insert that is complimentary in dimension to the recess into which it is to be placed.

11. A fabrication method for providing a relatively smooth surface, the smooth surface associated with lightning strike protection for composite materials joined with fasteners recessed below the smooth surface, said method comprising:

providing a preformed dielectric insert having a backing material removably coupled to a first surface of the preformed dielectric insert;

coating at least one of a head of the recessed fastener and a second surface of the preformed dielectric insert with an adhesive;

positioning the removable backing material on the smooth surface such that the preformed dielectric insert is inserted into a recess defined above the head of the recessed fastener, such that a portion of the adhesive is dispersed from the at least one of the head of the recessed fastener and the second surface of the preformed dielectric insert onto walls defining the recess, wherein at least a portion of the preformed dielectric insert is an elastomer; and

removing, without using a blade, any excess adhesive from the surface area of the composite material and the first surface of the insert.