Fastener systems and assemblies for coupling parts to composite structures and related methods

Abstract

This application discloses fastener systems and assemblies for attaching parts to a composite structure, as well as related methods. The fastener system can be used to attach parts to the composite structure such that at least a portion of the fastener system is embedded within the composite structure, and that the fastener system can be installed via proximity to only one side of the composite structure. Examples of fastener systems include sockets inserted through at least one layer of the composite structure and torque screws inserted into the sockets, thereby extending the sockets into an annular plate configured to distribute the force from the insertion of the torque screws. The annular plate is sealed between corresponding laminates of the composite structure, such that the fastener system is configured to attach parts to the composite structure directly or via structural connectors without the need for conventional drilling and bolting connections.

Description

Technical Field

[0001] The present disclosure relates to fastener systems and assemblies and related methods for coupling parts to composite structures. Background Art

[0002] Bolts or other fasteners are often used to secure parts to a composite structure via holes drilled in the composite structure. Such bolts are often heavy and labor intensive to install. Installation often requires access to both sides of the composite structure, which can be difficult in some cases. For example, when a part (e.g., a frame) is coupled to a composite structure such as the skin of an aircraft fuselage, access to the interior of the fuselage barrel can be very difficult, expensive, complicated, and / or time consuming. Securing frames, accessories, intercostal sections, and / or door surrounds to the fuselage skin often requires drilling thousands of holes in the skin, inserting fasteners on one side of the skin, and screwing a nut or ring onto each fastener on the opposite side of the skin. Even with the use of industrial robots, this technique requires multiple people to install such fasteners and access both sides of the composite structure. Summary of the invention

[0003] The fastener system of the present disclosure can be configured to fix a part (e.g., a frame) to a composite structure (e.g., an aircraft fuselage skin) without drilling holes in the composite structure and / or without access to both sides of the composite structure. An exemplary example of the fastener system of the present disclosure includes a socket, which is configured to be at least partially embedded in the composite structure using a torque screw, a ring plate and a structural connector. The socket includes a receiving portion configured to receive at least a portion of the torque screw. The size and shape of the torque screw can be designed relative to the socket so that when it is pressed into the receiving portion, it expands the receiving portion of the socket. The ring plate can be configured to be embedded in the composite structure and distribute the force from the torque screw being pressed into the receiving portion of the socket. The disclosed fastener system is configured to engage the part and the composite structure via a structural connector so that the fastener system connects the part to the composite structure. The disclosed assembly includes such a fastener system and a first laminate of a composite material and a second laminate of a composite material. The ring plate of the fastener system can be located between the first laminate and the second laminate. In some such assemblies, at least a portion of the structural connector of the fastener system may be positioned adjacent to the first laminate of the composite material.

[0004] According to the presently disclosed method, a fastener system may be partially assembled prior to installation in a composite structure. For example, a fastener assembly formed by a socket, a retainer, and a structural connector may be pre-assembled, and other components of the fastener system (e.g., a torque screw and a ring plate) may be added later. For example, a disclosed method of assembling a fastener assembly may include: providing a fastener assembly; positioning the retainer on the socket by sliding the retainer into a first retainer receiving recess and a second retainer receiving recess of the retainer; and positioning the structural connector on the socket. Positioning the structural connector may include compressing and / or plastically deforming a portion of the socket. In such a fastener assembly, the retainer may be configured to constrain the socket around the torque screw, and / or configured to prevent over-expansion of the socket when the torque screw is inserted into the socket.

[0005] The disclosed method of installing a fastener system for coupling a part to a composite structure generally includes embedding at least a portion of the fastener system between layers of the composite structure. For example, the method may include forming a first laminate of a composite material, the first laminate having a receiving hole formed therethrough; and positioning a fastener assembly relative to the first laminate of the composite material so that a socket of the fastener assembly is at least partially inserted through the receiving hole. In such an arrangement, the first laminate of the composite material may engage a structural connector of the fastener assembly. The socket, structural connector, and retainer of the fastener assembly may be assembled together before positioning the fastener assembly relative to the first laminate, or such a fastener assembly may be assembled when building the composite structure. The method may include securing an intermediate laminate of the composite material to a first upper surface of the first laminate of the composite material. The intermediate laminate of the composite material may include a pocket configured to receive at least a portion of the socket therein. The pocket may further be configured to receive an annular plate of the fastener system, and thus the method may include positioning the annular plate on the socket and in the pocket of the intermediate laminate of the composite material so that a lower plate surface of the annular plate engages a first upper surface of the first laminate of the composite material.

[0006] The method may further include inserting a torque screw of the fastener system into the socket and applying an outer laminate of the composite material covering the annular plate and at least a portion of the intermediate laminate of the composite material, thereby embedding the annular plate between the outer laminate of the composite material and the first laminate of the composite material. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] Figure 1 is a perspective view of an aircraft that may be formed from one or more composite structures including one or more fastener systems and / or fastener assemblies according to the present disclosure.

[0008] Figure 2is a schematic block diagram representation of a non-exclusive example of a fastener system including a fastener assembly according to the present disclosure.

[0009] Figure 3 is a cross-sectional view of an example of a fastener system according to the present disclosure.

[0010] Figure 4 is a perspective view of one example of a receptacle of a fastener system according to the present disclosure.

[0011] Figure 5 is a perspective view of one example of a retainer of a fastener system according to the present disclosure.

[0012] Figure 6 is a perspective view of one example of a torque screw of a fastener system according to the present disclosure.

[0013] Figure 7 is a perspective view of one example of a fastener assembly according to the present disclosure.

[0014] Figure 8 is a perspective view of one example of a structural connector of a fastener system according to the present disclosure.

[0015] Fig. 9 According to the present disclosure Figure 7 A side view of a fastener assembly engaged with a first laminate of composite material.

[0016] Fig.10 According to the present disclosure Fig. 9 A perspective view of a fastener assembly and a first laminate joined with an intermediate laminate of a composite material.

[0017] Fig.11 According to the present disclosure Fig.10 A perspective view of a fastener assembly showing the insertion of an example of a collar plate and torque screw of a fastener system.

[0018] Fig.12 is a bottom perspective view of an example of a collar plate of a fastener system according to the present disclosure.

[0019] Fig.13 is a top view of an example of a socket of a fastener system according to the present disclosure.

[0020] Fig.14 According to the present disclosure Fig.11 A perspective view of the fastener assembly showing the application of the second laminate of composite material.

[0021] Fig.15 is a schematic flow chart of a method of assembling a fastener assembly according to the present disclosure.

[0022] Fig.16 is a schematic flow chart of a method of installing a fastener system for coupling a part to a composite structure according to the present disclosure. DETAILED DESCRIPTION

[0023] refer to Figure 1 , one or more composite structures 10 may be included in the device 12. The composite structure 10 may be used in many different industries and applications, such as the aerospace, automotive, electronics, construction, military, entertainment, and / or racing industries. Figure 1 1, an example of an apparatus 12 that may include one or more composite structures 10 is generally shown in the form of an aircraft 14. The aircraft 14 may take any suitable form, including a commercial aircraft, a military aircraft, or any other suitable aircraft. Figure 1 The aircraft 14 is shown in the form of a fixed-wing aircraft, but other types and configurations of aircraft are within the scope of aircraft 14 according to the present disclosure, including, but not limited to, rotorcraft and helicopters.

[0024] An apparatus 12 (e.g., an aircraft 14) may include one or more composite structures 10. As illustrative, non-exclusive examples, the composite structure 10 may be used in aircraft structures such as a wing 16, a fuselage 18 or fuselage sections 18a, 18b, 18c, a horizontal tail 20, an overhead storage bin 22, a vertical tail 24, and an engine cowling 26; however, other components of the aircraft 14 may additionally or alternatively include the composite structure 10. Other applications for the composite structure 10 in the aircraft 14 include floors, interior walls, food handling galley assemblies, wing control surfaces, passenger storage racks, thrust deflector assemblies, cabin panels, ablation shields for nose cones, instrument housings and racks, and bulkhead panels. In other industries, examples of equipment 12 (including one or more composite structures 10) may include or be part of a space satellite, an electronic radome structure, a transport, a shipping container, a shelter, a large antenna or disk reflector, a refrigeration panel, a rapid transit floor, an electronic deck shelter on a ship, a cargo pallet, a vehicle body, a building curtain wall, a partition, a divider, an expandable hospital shelter, and / or an internal structure of a component. One or more fastener systems 30 may be included in an aircraft 14 (or other equipment 12) to couple one or more parts to one or more composite structures 10. In one specific example, a plurality of fastener systems 30 may couple a frame to an aircraft fuselage 18.

[0025] Figure 2Non-exclusive examples of fastener systems 30 and fastener assemblies 32 according to the present disclosure are schematically shown. Generally, elements that are likely to be included in a given (i.e., specific) example are shown in solid lines, while elements that are optional for a given example are shown in dashed lines. However, elements shown in solid lines are not required for all examples, and elements shown in solid lines may be omitted from a specific example without departing from the scope of the present disclosure.

[0026] like Figure 2 As shown schematically, fastener system 30 generally includes a socket 34, a torque screw 36, and an annular plate 38. Fastener system 30 is configured to couple part 40 to composite structure 42 (where composite structure 10 is an example of composite structure 42). Together, the components of fastener system 30 are configured to couple part 40 to composite structure 42 by accessing a single side of composite structure 42 without drilling a hole through composite structure 42. Specifically, as will be described in detail in conjunction with other figures, fastener system 30 is configured to be at least partially embedded within composite structure 42, thereby fixing fastener system 30 relative to the composite structure. Part 40 can then be coupled to fastener system 30, thereby also effectively coupling part 40 to composite structure 42. Thus, fastener system 30 engages part 40 and composite structure 42, such that it couples part 40 to composite structure 42.

[0027] The socket 34 is configured to be at least partially embedded in the composite structure 42, and the torque nail 36 is configured to be at least partially received in the socket 34, for example, at least partially received in the receiving portion 44 of the socket 34. The size and shape of the torque screw 36 can be designed relative to the socket 34 so that the receiving portion 44 is expanded when the torque screw 36 is pressed into the receiving portion 44. The ring plate 38 is also configured to be at least partially embedded in the composite structure 42 so as to distribute the force from the torque screw 36 when the torque screw 36 is pressed into the socket 34 (for example, pressed into the receiving portion 44 of the socket 34). The socket 34 can be configured to effectively serve as an anchor component to anchor the fastener system 30 to the composite structure 42.

[0028] In some examples, the disclosed fastener system 30 may be configured to utilize a single fastener system 30 to install a part 40 (e.g., a shear strap) rather than using multiple bolts or other fasteners for each part 40. This reduction and / or elimination of bolt use and the corresponding reduction and / or elimination of drilling through the composite structure 42 allows for loose tolerances of the composite structure 42 in some examples, which can reduce waste caused by having to scrap composite structures that exceed tolerances. Additionally or alternatively, the disclosed fastener system 30 can reduce and / or eliminate the need for grinding during manufacturing, for example, due to the reduction and / or elimination of drilling steps. Additionally or alternatively, the disclosed fastener system 30 can reduce and / or eliminate the need for filling when securing the part 40 to the composite structure 42 by zeroing out any irregularities in the composite structure 42. Additionally or alternatively, the disclosed fastener system 30 can be configured to be installed only close to one side of the composite structure 42.

[0029] The assembly 50 (also referred to herein as the system 50) can thus be formed by the fastener system 30 and the composite structure 42. The composite structure 42 typically includes a plurality of laminates of a composite material, such as a first laminate 52, a second laminate 54, and / or an intermediate laminate 56, when included, the intermediate laminate 56 is located between the first laminate 52 and the second laminate 54. As is well known to those skilled in the art, each of the first laminate 52, the second laminate 54, and / or the intermediate laminate 56 typically includes multiple composite material layers or plies. For example, the first laminate 52, the second laminate 54, and / or the intermediate laminate 56 can all be formed by one or more layers of polymer-reinforced carbon fibers. When the fastener system 30 is secured to the composite structure 42, the ring plate 38 is located between the first laminate 52 and the second laminate 54. In some examples, the laminate thickness 58 of the intermediate laminate 56 of the composite material may be substantially equal to the plate thickness 59 of the annular ring plate 38 , such that the annular ring plate 38 is substantially flush with the intermediate laminate 56 .

[0030] The assembly 50 may also include a structural connector 60, which may be part of and / or coupled to the fastener system 30. The structural connector 60 is used to couple the part 40 to the fastener system 30. When assembled, at least a portion of the structural connector 60 may be positioned adjacent to the first laminate 52 of the composite structure 42.

[0031] The components of the fastener system 30 (e.g., the socket 34, the torque screw 36, the ring plate 38 and / or the structural connector 60) may be formed of any suitable material, including but not limited to polymers, metals and / or polymer-reinforced composite materials (e.g., polymer-reinforced carbon fiber). In some examples, one or more components of the fastener system 30 may be formed of the same material. For example, the socket 34 and the torque screw 36 may be formed of the same metal. Additionally or alternatively, one or more components of the fastener system 30 may be formed of materials different from each other. In a specific example, the fastener system 30 may be formed of a carbon fiber composite material. In some examples, the components of the fastener system 30 may be fixed together using a flexible sealant. In an example where different components of the fastener system 30 have different coefficients of thermal expansion, the corresponding materials of one or more components may be selected in response to changes in temperature to account for or offset the expansion or contraction of one or more other components of the fastener system 30. For example, the fastener system 30 may include one or more components formed from a material having a negative coefficient of thermal expansion such that the one or more corresponding components may expand when exposed to reduced temperatures, as opposed to one or more other corresponding components of the fastener system 30 that may be configured to contract when exposed to reduced temperatures.

[0032] In some specific examples, the composite structure 42 may be an aircraft fuselage (e.g., the aircraft fuselage 18), wherein the first laminate sheet 52 of the composite material is an inner skin 62 of the aircraft fuselage 18, and the second laminate sheet 54 of the composite material is an outer skin 64 for the aircraft fuselage 18. In this manner, the first inner surface 66 of the first laminate sheet 52 of the composite material may be arranged to face the interior space of the aircraft fuselage 18, while the first outer surface 68 of the first laminate sheet 52 of the composite material is opposite to the first inner surface 66 and faces the second laminate sheet 54 of the composite material.

[0033] Now go to Figures 3 to 14 , illustrative, non-exclusive examples of system 50, fastener system 30, and / or components thereof are shown in the form of system 51, fastener system 61, and components thereof. Where appropriate, Figure 2 Reference numerals in the schematic diagram are used to indicate corresponding components of the system 51, fastener system 61, and / or components thereof; however, Figures 3 to 14 The examples are non-exclusive and do not limit the system 50, fastener system 30 and / or its components to Figures 3 to 14 That is, the system 50, fastener system 30 and / or its components are not limited to Figures 3 to 14 The specific examples shown in Figure 2 Schematic representation and / or Figures 3 to 14Any number of the various aspects, configurations, features, attributes, etc. shown and discussed in the examples of the present invention and its variations are not necessarily included in all of these aspects, configurations, features, attributes, etc. For the sake of brevity, each previously discussed component, part, part, aspect, region, etc. or its variations are relative to Figures 3 to 14 Each of the above may no longer be discussed, illustrated, and / or labeled; however, the system 51, fastener system 61, and / or components thereof may utilize previously discussed features, variations, etc., which are within the scope of the present disclosure, and vice versa.

[0034] Figure 3 A schematic cross-sectional view of a system 51 is shown, which is assembled with a fastener system 61 partially embedded in a composite structure 43 (which is an example of a composite structure 42 and includes a first laminate 52 of a composite material and a second laminate 54 of a composite material). The structural connector 60 engages a socket 70 (which is an example of a socket 34) so ​​that at least a portion of the structural connector 60 is positioned adjacent to the first laminate 52 of the composite material. The fastener system 61 also includes a torque screw 80 (which is an example of a torque screw 36) inserted into the socket 70 and an annular plate 90 (which is an example of an annular plate 38) engaged with the socket 70 and embedded in the composite structure 43. The retainer 100 also engages the socket 70, as will be described in further detail herein. Therefore, the socket 70 is configured to engage multiple other components of the fastener system 61.

[0035] For the sake of clarity, Figure 4 A socket 70 of the fastener system 61 is shown separated from the other components of the fastener system 61. The socket 70 includes a first elongated groove surface 71 having a plurality of first socket grooves 72 formed therein, and also includes a second elongated groove surface 73 having a plurality of second socket grooves 74 formed therein. The plurality of first and second socket grooves 72, 74 are configured to engage the ring plate 90.

[0036] The socket 70 also includes a receiving portion 44 defined by a first interior receiving surface 75 and a second interior receiving surface 76. The receiving portion 44 is configured to receive a torque screw 80 such that when the torque screw 80 is positioned within the receiving portion 44, the torque screw 80 engages the first and second interior receiving surfaces 75, 76. A flex region 77 is formed on one end of the socket 70, and a second flex region 77' is formed on the other end of the socket 70 opposite the flex region 77. The flex regions 77, 77' extend between the first interior receiving surface 75 and the second interior receiving surface 76. The flex regions 77, 77' are configured to bend and / or compress to accommodate engagement of other components with the socket 70 when the fastener system 61 is assembled. Flexing of the socket 70 via the flex regions 77, 77' allows the first and second elongated groove surfaces 71, 73 to be temporarily and oppositely forced together when the ring plate 90 is positioned on the socket 70. Additionally or alternatively, the flexure of the socket 70 via the flexure regions 77, 77' can allow the receiving portion 44 to expand (e.g., the first and second elongated groove surfaces 71, 73 can be forced further apart) when the torque screw 80 is inserted into the receiving portion 44. By intentionally designing the flexure regions 77, 77' to accommodate a certain amount of such flexure, for example, the force generated by the engagement of the torque screw 80 presses outwardly on the first inner receiving surface 75 and the second inner receiving surface 76, which can force these surfaces away from each other. For example, in various embodiments of the socket 70, the thickness 121 ( Fig.13 ) can be increased or decreased to accommodate the desired amount of flex or compliance for various structures of the socket 70.

[0037] In some examples, at least a portion of the first interior receiving surface 75 is knurled. Additionally or alternatively, at least a portion of the second interior receiving surface 76 can be knurled. Additionally or alternatively, at least a portion of the first interior receiving surface 75 and / or at least a portion of the second interior receiving surface 76 can be smooth.

[0038] In order to engage the retainer 100, the socket 70 includes a first retainer receiving recess 78 and a second retainer receiving recess 79 disposed opposite to each other. The socket 70 is configured to receive the retainer 100 in the first retainer receiving recess 78 and the second retainer receiving recess 79. For example, Figure 5As shown, the retainer 100 can be an elongated U-shaped retainer 100 having a first elongated portion 101 and a second elongated portion 102. When the retainer 100 is positioned on the socket 70, the first elongated portion 101 of the retainer 100 can be positioned within and / or engaged with the first retainer receiving recess 78, and the second elongated portion 102 can be positioned within and / or engaged with the second retainer receiving recess 79. In some examples, the length 104 of the retainer 100 is approximately equal to the length 81 ( Figure 4 ), such that the ends 105 of the first and second elongated portions 101, 102 may be substantially flush with the socket 70 when the holder 100 is placed on the socket 70. In other examples, the length 104 of the holder 100 may be less than the length 81 of the socket 70. In other examples, the length 104 of the holder 100 may be greater than the length 81 of the socket 70 such that the ends 105 extend beyond the socket 70.

[0039] The retainer 100 may be slidably engaged with the first retainer receiving recess 78 and the second retainer receiving recess 79 of the socket 70. In other examples, the retainer 100 is press-fit or friction-fitted with the first retainer receiving recess 78 and the second retainer receiving recess 79. The retainer 100 is generally configured to constrain the socket 70, for example, when the socket 70 receives outward pressure from the insertion of the torque screw 80, the expansion of the socket 70 via the flexion areas 77, 77' is limited and / or prevented. In addition or alternatively, the retainer 100 may be configured to retain and / or constrain the socket 70 around the torque screw 80 once the torque screw 80 is inserted into the socket 70 to retain the torque screw 80 in the socket 70. The retainer 100 may be positioned on the socket 70 before the torque screw 80 is inserted, or positioned on the socket 70 after the torque screw 80 is inserted into the socket 70. In some examples, the retainer 100 may include one or more bores 106 for receiving one or more corresponding fasteners that secure the retainer 100 to the socket 70. In a specific example, the retainer 100 is positioned on the socket 70 before the torque screw 80 is inserted, and one or more fasteners may also be installed in the bore 106 of the retainer 100 before the torque screw is inserted into the socket 70. Once the retainer is positioned on the socket 70, such fasteners may be used to tighten the retainer 100 around the socket 70. Such fasteners may be configured to extend when the torque screw 80 is inserted into the socket 70 and pressed outwardly on the socket 70. One or more fasteners may be installed in or through the bore 106 and then tightened before the torque screw 80 is inserted. In some examples, when the torque screw 80 is inserted, it is configured to apply a secondary torque by extending the fastener inserted into the bore 106.

[0040] like Figure 5As shown, in some examples of the retainer 100, the first elongated portion 101 is substantially parallel to the second elongated portion 102. Figure 5 In the example of the retainer 100 shown, the first elongated portion 101 is spaced apart from the second elongated portion 102 by a distance 107 sufficient to accommodate the torque screw 80 inserted into the socket 70. For example, the distance 107 may be at least equal to the width 82 ( Figure 6 ). The distance 107 may be defined by a connecting member 103 connecting the first elongated portion 101 to the second elongated portion 102. In some examples, the connecting member 103 is a vertical member 103 that is substantially perpendicular to the first elongated portion 101 and the second elongated portion 102. Thus, the retainer 100 has a straight U-shape in this example, but in other examples, the first and second elongated portions 101, 102 may not be parallel to each other, and / or the connecting member 103 may not be perpendicular to the first elongated portion 101 and / or the second elongated portion 102.

[0041] The socket 70 is also configured to receive the structural connector 60. The retainer 100 and / or the structural connector 60 may be connected to the socket 70 prior to use by the manufacturer. For example, a supplier may couple the retainer 100 and / or the structural connector 60 to the socket 70 and attach the final fastener assembly 32 ( Figure 2 ; Figure 7 ) are provided to manufacturers as kits. Figure 7 As shown, the fastener assembly 32 may include a socket 70 that engages, couples, and / or positions the retainer 100 and the structural connector 60. Figure 4 and Figure 5 As discussed, the retainer 100 engages with the socket 70. Figure 8 As shown, the structural connector 60 (here shown as an example of a shear strap 65) can have an elongated curved L-shape, but the structural connector 60 can take any suitable shape. In various examples, the structural connector 60 can be a shear strap, a fitting, a bracket, an intercostal, and / or any other structural connector configured to engage parts and composite structures. Regardless of the form of the structural connector 60, it generally includes a slot-shaped opening 67, also referred to herein as a slot 67, wherein the slot-shaped opening 67 is configured to receive a socket 70 therefrom so as to engage the socket 70. In the example where the structural connector 60 is a shear strap 65, the slot-shaped opening 67 can be a shear strap slot 69.

[0042] To secure the structural connector 60 to the socket 70, a portion of the socket 70 may be inserted through the slot-shaped opening 67. For example, the lower portion 84 of the socket 70 may be inserted through the slot-shaped opening 67 of the structural connector 60 to engage the structural connector 60 and the socket 70. In other examples, the upper portion 85 of the socket 70 (e.g., the first elongated groove surface 71 and the second elongated groove surface 73) may be inserted through the slot-shaped opening 67 to engage the structural connector 60 and the socket 70. In some examples, it may be necessary to press the first elongated groove surface 71 and the second elongated groove surface 73 closer together via the flexure regions 77, 77' to facilitate insertion of the upper portion 85 through the slot-shaped opening 67. Once the structural connector 60 is fully inserted into the receptacle 70, the first and second elongated groove surfaces 71, 73 may spring back or return to their original unstressed positions, which may essentially serve to lock the structural connector 60 in place, thereby retaining the structural connector on the receptacle 70 by virtue of the width of the upper portion 85 being greater than the width of the slot-shaped opening 67 of the structural connector 60. The retainer 100 may be positioned on the receptacle 70 after the structural connector 60 is engaged with the receptacle 70, or before the structural connector 60 is engaged with the receptacle 70.

[0043] As in Figure 3 Best seen in, and also referenced Figure 4 When the structural connector 60 is engaged with the socket 70 , the structural connector 60 may engage with the first outer wall 86 of the socket 70 , the first lower surface 87 of the first elongated groove surface 71 , the second outer wall 88 of the socket 70 , and / or the second lower surface 89 of the second elongated groove surface 73 .

[0044] Reference now Fig. 9 , the fastener assembly 32 is engaged with the first laminate 52 of the composite material. In some specific examples, the first laminate 52 of the composite material can be an inner skin of an aircraft, such as an inner skin of an aircraft fuselage. Similar to the narrow slot-shaped opening 67 of the structural connector 60, the first laminate 52 includes a receiving hole 91, through which a portion of the socket 70 can be inserted to engage the fastener assembly 32 with the first laminate 52. The receiving hole 91 generally extends from the first inner surface 66 of the first laminate 52 to the first outer surface 68. As shown in FIG. Fig. 9 As shown, at least a portion 92 of the structural connector 60 is positioned adjacent to the first laminate board 52, such as adjacent to the first inner surface 66 of the first laminate board 52, and is considered to engage the first inner surface 66. In this example, the portion 92 of the structural connector 60 is sandwiched between the retainer 100 and the first inner surface 66 of the first laminate board 52. The receiving hole 91 of the first laminate board 52 can be positioned relative to the socket 70 so that the first laminate board 52 engages the first elongated groove surface 71 and the second elongated groove surface 73 of the socket 70.

[0045] like Fig.10 As shown, the composite intermediate laminate 56 is applied to the first outer surface 68 of the first laminate 52. The intermediate laminate 56 includes a pocket 93 configured to receive a portion of the fastener assembly 32 and a collar plate 90, such as Fig.11 The size and shape of the ring plate 90 can be designed relative to the intermediate laminate 56 and the pocket 93 so that when the ring plate 90 is positioned in the pocket 93, the upper ring plate surface 94 of the ring plate 90 is substantially flush with the outer surface 95 of the intermediate laminate 56. For example, the plate thickness 59 ( Figure 2 , Fig.12 ) may be substantially equal to the intermediate laminate 56 ( Figure 2 ) laminate thickness 58. Fig.11 As best seen in , the size and shape (e.g., surface area) of the annular plate 90 can be substantially the same as the size and shape of the pocket 93 of the intermediate laminate 56. For example, the outer panel perimeter of the annular plate 90 can have substantially the same size and shape as the pocket perimeter 119 of the pocket 93, so that the annular plate 90 fits securely within the pocket 93. In some examples, the annular plate 90 can have a sliding fit, a friction fit, or a press fit relative to the pocket perimeter 119 of the pocket 93. In some examples, when the annular plate 90 is inserted into the pocket 93, a small gap may exist between the outer panel perimeter 118 and the pocket perimeter 119. In some examples, when the annular plate 90 is positioned, such a gap can be filled with a filler material and / or resin. In some examples, the pocket 93 may be formed around the collar plate 90 (eg, the collar plate 90 may be positioned on the first laminate 52 prior to applying the intermediate laminate 56 ).

[0046] refer to Fig.11 and Fig.12 , the ring plate 90 includes an opening 46 configured to receive the socket 70 therethrough (but for clarity, Fig.12The annular plate 90 is shown without the socket 70). Therefore, by positioning the annular plate 90 within the pocket area 93, the annular plate 90 can be engaged with the fastener assembly 32 (and the fastener system 61) so that the first elongated groove surface 71 and the second elongated groove surface 73 of the socket 70 are at least partially inserted through the opening 46 of the annular plate 90. Therefore, the size and shape of the opening 46 of the annular plate 90 can be designed so that it fits on the first elongated groove surface 71 and the second elongated groove surface 73 of the socket 70. In some instances, it may be necessary to compress the first elongated groove surface 71 and the second elongated groove surface 71 closer together via the flex regions 77, 77' so that the upper portion 85 of the socket 70 is inserted through the opening 46. In this way, the flex regions 77, 77' can be configured to allow sufficient movement of the socket 70 to allow the annular plate 90 to be positioned on the socket 70. The annular plate thickness 59 ( Fig.12 ) may be such that an upper ring plate surface 94 of the ring plate 90 is substantially flush with an upper socket surface 96 of the socket 70 when the ring plate 90 is positioned within the pocket 93 of the fastener system 61 .

[0047] like Fig.12 As shown, the ring plate 90 includes a plurality of first stepped grooves 97 and a plurality of second stepped grooves 98 disposed opposite to each other and partially defining the opening 46. Figure 3 As best shown, when the ring plate 90 is engaged with the fastener assembly 32, the plurality of first stepped grooves 97 engage with the plurality of first socket grooves 72 and the plurality of second stepped grooves 98 engage with the plurality of second socket grooves 74. Fig.12 , a plurality of first stepped grooves 97 may be formed on a first inclined surface 108 of the opening 46, and a plurality of second stepped grooves 98 may be formed on a second inclined surface 109 of the opening 46. Generally, the first inclined surface 108 and the second inclined surface 109 are not perpendicular to the upper ring plate surface 94 and are not perpendicular to the lower ring plate surface 99 (the lower ring plate surface 99 is opposite to the upper ring plate surface 94), and the opening 46 extends from the upper ring plate surface 94 to the lower ring plate surface 99. In other words, the height 110 of the opening 46 may be equal to the ring plate thickness 59. As shown in FIG. Figure 3 As best shown, the collar plate 90 is generally arranged in the fastener system 51 so that a portion of the structural connector 60 engages the socket 70 between the retainer 100 and the collar plate 90 (in this example, the composite first laminate 52 is also located between the retainer 100 and the collar plate 90).

[0048] refer to Figure 3 , Figure 6 and Fig.11, the torque screw 80 is positioned within the socket 70, thereby expanding the receiving portion 44 of the socket 70 against the annular plate 90. In some examples, the plurality of first stepped grooves 97 and the plurality of second stepped grooves 98 of the annular plate are configured to deform when the torque screw 80 is inserted into the receiving portion 44 of the socket 70. Similarly, in some examples, the plurality of first socket grooves 72 and the plurality of second socket grooves 74 are deformed when the torque screw 80 is inserted into the socket 70. Due to the expansion and deformation of the socket 70 by the insertion of the torque screw 80, a locking engagement may be formed between the socket 70 and the annular plate 90 (e.g., between the stepped grooves 97, 98 of the annular plate 90 and the socket grooves 72, 74 of the socket 70). The size and shape of the annular plate 90 are designed to distribute the load from the torque screw 80 being inserted. For example, the collar plate 90 may be configured to adequately distribute load within the composite structure 43 when the torque screw 80 is inserted into the socket 70 , thereby avoiding damage to the first laminate 52 , the intermediate laminate 56 , the second laminate 54 , and / or the structural connector 60 .

[0049] In order to receive the torque screw 80, the socket 70 includes a slot-shaped opening 111, which Fig.13 The lower portion 83 ( Figure 3 and Figure 6 ) is inserted through the slot-shaped opening 111 when the torque screw 80 is inserted into the socket 70. The slot-shaped opening 111 extends substantially along the entire length 112 of the socket 70 between the flexure region 77 and the flexure region 77'. When the torque screw 80 is fully inserted into the socket 70, the lower portion 83 of the torque screw 80 is received between the first pressing surface 113 and the second pressing surface 114 of the socket 70, as shown in FIG. Figure 3 and Figure 4 Best seen. In some examples, when the torque screw 80 is inserted into the socket 70, the torque screw 80 deforms the first extrusion surface 113 and the second extrusion surface 114. Additionally or alternatively, when the torque screw 80 is positioned within the socket 70, the lower portion 83 of the torque screw 80 can be pressed outwardly on the first extrusion surface 113 and the second extrusion surface 114. The torque screw 80 can thus be configured to apply force to both the upper portion 85 (e.g., the first elongated groove surface 71 and the second elongated groove surface 73) of the socket 70 and the lower portion 84 (e.g., the first extrusion surface 113 and the second extrusion surface 114) of the socket 70. In some examples, when the retainer 100 is positioned on the socket 70, the retainer 100 is pressed inwardly on the first extrusion surface 113 and the second extrusion surface 114.

[0050] like Figure 6As best seen, the torque screw 80 includes a wedge-shaped portion 115 that may be coupled to or integrally formed with the lower portion 83. The wedge-shaped portion 115 includes a first engagement surface 116 and a second engagement surface 117 that are configured to engage with the socket 70 when the torque screw 80 is inserted into the socket 70. For example, Figure 3 As best seen in the drawings, the wedge-shaped portion 115 is configured to be received in the receiving portion 44 of the socket 70 such that the first engagement surface 116 engages the first interior receiving surface 75 of the socket 70 and such that the second engagement surface 117 engages the second interior receiving surface 76 of the socket 70. The first and second engagement surfaces 116, 117 are generally angled such that the torque screw 80 tapers from the upper surface 120 toward the lower portion 83. In this manner, the torque screw 80 can be configured such that the torque screw 80 is squeezed outwardly from within the socket 70 the further the torque screw 80 is driven into the receiving portion 44 of the socket 70. The socket 70 can be sized relative to the torque screw 80 such that when the torque screw 80 is inserted or driven into the socket 70, the socket 70 is forced to expand (e.g., by forcing the first elongated groove surface 71 away from the second elongated groove surface 73).

[0051] In some examples, at least a portion of the first engagement surface 116 is knurled. Additionally or alternatively, at least a portion of the second engagement surface 117 may be knurled. As a non-limiting illustrative example, Figure 6 As shown, a portion of the first engagement surface 116 indicated by the bracket 122 (and a corresponding portion of the second engagement surface 117) may be knurled in some examples, while a portion of the first and second engagement surfaces 116, 117 indicated by the bracket 123 may be a generally smooth surface. Of course, in various examples of the torque screw 80, some or all of the first and / or second engagement surfaces 116, 117 may be knurled, and / or some or all of the first and / or second engagement surfaces 116, 117 may be generally smooth. In other words, in various examples, the portions indicated by the brackets 122, 123 may be larger or smaller than the first and / or second engagement surfaces 116, 117, respectively. Figure 6 Additionally or alternatively, the relative positions of the portions indicated by the braces 122, 123 may be switched. In some examples, the first engagement surface 116 and the second engagement surface 117 may include knurled and / or smooth portions spaced apart from each other, such as distributed at discrete locations on the first and second engagement surfaces 116, 117.

[0052] In some examples, the torque screw 80, the ring plate 90 and / or the socket 70 may all be formed of the same material, such as the same metal, polymer or composite material. In other examples, the torque screw 80, the ring plate 90 and / or the socket 70 may be formed of different materials. For example, the torque screw 80, the ring plate 90 and / or the socket 70 may be formed of different metals, different polymers and / or different composite materials. In some examples, the torque screw 80 may be formed of metal, and the socket 70 may be formed of polymer, and vice versa. A combination of friction, deformation and / or self-diffusion may be used to combine the torque screw 80 and the socket 70. Additionally or alternatively, a combination of friction, deformation and / or self-diffusion may be used to combine the ring plate 90 and the socket 70. In an example where these components are combined at least in part by self-diffusion, at least a portion of each corresponding component may be formed of the same material. For example, at least a portion of the torque screw 80 may be formed of the same metal as at least a portion of the socket 70, so that self-diffusion may occur where those corresponding parts are engaged with each other. Similarly, at least a portion of the annular plate 90 may be formed of the same metal as at least a portion of the socket 70 so that self-diffusion can occur where those respective portions engage one another. In some examples, the area configured for self-diffusion may be smoothed to facilitate such self-diffusion. Additionally or alternatively, at least a portion of the annular plate 90, the torque screw 80, and / or the socket 70 may be knurled or roughened to frictionally engage with other respective surfaces.

[0053] like Fig.11 As shown, once the torque screw 80 and the ring plate 90 are positioned, the second laminate 54 of the composite material can be applied, thereby enclosing the ring plate 90 between the first laminate 52 and the second laminate 54, as shown in FIG. Fig.14 As shown. The second laminate 54 can be applied to the upper ring plate surface 94 and the outer surface 95 of the middle laminate 56 so that the torque screw 80 and a portion of the socket 70 are enclosed in the composite structure 43. In a specific example, the composite structure 43 can be an aircraft fuselage, the first laminate 52 is the inner skin of the fuselage, and the second laminate 54 is the outer skin of the fuselage. The fastener system 61 can therefore be used to secure parts to the composite structure 43 without drilling holes in the first laminate 52 and the second laminate 54. Such parts may include, for example, frames, accessories and / or brackets for an aircraft fuselage, and may be directly secured to the composite structure 43 via the fastener system 61, or may be secured to the composite structure 43 via the structural connector 60.

[0054] Fig.15 and Fig.16 Schematically provided is a flow chart representing an illustrative, non-exclusive example of a method according to the present disclosure. Fig.15 and Fig.16 In the embodiment of the present invention, some steps are shown in dashed boxes, indicating that these steps may be optional or may correspond to optional versions of the method according to the present disclosure. That is, it is not required that all methods according to the present disclosure include the steps shown in solid boxes. As understood from the discussion herein, Fig.15 and Fig.16 The methods and steps shown are not limiting, and other methods and steps are within the scope of the present disclosure, including methods having more or less than the number of steps shown.

[0055] Fig.15 A method 200 of assembling a fastener assembly (e.g., fastener assembly 32) to a composite structure (e.g., composite structure 42) is shown. Method 200 generally includes, at 202, positioning a retainer (e.g., retainer 100) of the fastener assembly on a receptacle (e.g., receptacle 34) of the fastener assembly. Method 200 also includes, at 204, positioning a structural connector (e.g., structural connector 60) of the fastener assembly on the receptacle, the fastener assembly being configured to couple a part to a composite structure via the structural connector. Positioning the structural connector on the receptacle at 204 may include compressing and / or plastically deforming a portion of the receptacle, such as first and second elongated groove surfaces 71, 73 of receptacle 70. In some examples, positioning the structural connector at 204 also includes returning the portion of the receptacle to its unstressed state, thereby securing the structural connector to the receptacle.

[0056] In some specific examples, positioning the retainer at 202 includes sliding the retainer into a first retainer receiving recess (e.g., first retainer receiving recess 78) and a second retainer receiving recess (e.g., second retainer receiving recess 79) of the socket. Some methods 200 include installing at least one fastener on the retainer at 206 to fasten and / or secure the retainer around the socket. In some examples, positioning the retainer at 202 is performed after positioning the structural connector at 204. In other examples, positioning the retainer at 202 is performed before positioning the structural connector at 204. In some examples, positioning the structural connector at 204 may include contacting the retainer with the structural connector.

[0057] Some methods 200 include forming a slot-shaped opening (e.g., slot-shaped opening 67) in the structural connector at 208, wherein forming the slot-shaped opening at 208 is performed before positioning the structural connector on the socket at 204. Forming the slot-shaped opening at 208 generally includes forming such a slot-shaped opening that is sized and shaped to fit over a portion of the socket (e.g., upper portion 85 or lower portion 84) to secure the structural connector to the socket. In some examples, the method 200 may be performed before the fastener system is installed in the composite structure and / or at a location remote from the location where the fastener system is installed in the composite structure. For example, the method 200 may be performed by a supplier to provide a fastener assembly for use by a manufacturer. In other examples, the method 200 may be performed substantially simultaneously with other steps of installing the fastener system of the present disclosure and / or at the same location.

[0058] Fig.16 A method 300 of installing a presently disclosed fastener system (e.g., fastener system 30) is shown. Such a fastener system may be used to attach a part to a composite structure, such as attaching a frame to an aircraft fuselage skin, without drilling holes in the skin for such attachment. Method 300 generally includes forming a first laminate (e.g., first laminate 52) of a composite material having a receiving hole (e.g., receiving hole 91) formed therethrough at 302; and positioning a fastener assembly (e.g., fastener assembly 32) relative to the first laminate of the composite material at 304 such that a socket (e.g., socket 70) of the fastener assembly is at least partially inserted through the receiving hole of the first laminate and such that the first laminate engages a structural connector (e.g., structural connector 60) of the fastener assembly. In some instances, positioning the fastener assembly at 304 may be performed by accessing the first laminate via an inner surface of the first laminate (corresponding to an interior region of the composite structure). In some methods 300, prior to positioning the fastener assembly at 304, for example by performing a combination of the above Fig.15 In any of the detailed methods 200, the fastener assembly is assembled at 200. Assembling the fastener assembly at 200 may also include selecting a thickness of a flexure region of the socket (e.g., thickness 121 of flexure regions 77, 77') such that the flexure region is sufficiently compliant to allow insertion of a torque screw and / or an annular plate of the fastener system.

[0059] In some specific examples, positioning the fastener assembly at 304 may include positioning the fastener assembly so that a portion of the structural connector is located between the first laminate of the composite material and a retainer (e.g., retainer 100) of the fastener assembly. Once the fastener assembly is positioned relative to the first laminate at 304, an intermediate laminate (e.g., intermediate laminate 56) of the composite material is applied at 306. The intermediate laminate is applied to the first laminate at 306, and is generally applied to the first outer surface (e.g., first outer surface 68) of the first laminate. The intermediate laminate may be applied at 306 by being fixed to the first laminate, adhered to the first laminate, and / or laid directly on the first laminate. Applying the intermediate laminate at 306 includes applying a layer of material forming the intermediate laminate so that a pocket (e.g., pocket 93) is formed in the intermediate laminate, which is configured to receive at least a portion of the socket of the fastener assembly passing through it. The pocket is also configured to receive a ring plate (e.g., ring plate 90) of the fastener system. The pocket may be formed when the intermediate laminate is formed, such as by laying down a material layer with preformed openings therein such that the preformed openings of the layers are aligned when the intermediate laminate is formed to form the pocket in the intermediate laminate. In other examples, the pocket may be formed after the layers of the intermediate laminate are laid down, such as by cutting the pocket in the intermediate laminate. In other examples, applying the intermediate laminate at 306 may be performed by laying down a material layer around the annular plate such that the pocket is formed around the annular plate after the annular plate is placed on the first laminate.

[0060] Once the fastener assembly is positioned at 304, the annular plate may be positioned at 308 by placing the annular plate on the socket so that a portion of the socket is inserted through a slot-shaped opening (e.g., opening 46) formed in the annular plate. For example, when the annular plate is positioned, the first and second elongated groove surfaces (71, 73) of the socket may be inserted through the opening in the annular plate. When the annular plate is positioned at 308, a lower plate surface (e.g., lower annular plate surface 99) of the annular plate engages with a first upper surface (e.g., first outer surface 68) of the first laminate. In some methods 300, before the annular plate of the fastener system is positioned at 308, an intermediate laminate is applied at 306, wherein the annular plate is located within a pocket-shaped region of the intermediate laminate. In some methods 300, before the intermediate laminate is applied at 306, the annular plate is positioned at 308 so that a pocket-shaped region of the intermediate laminate is formed around the annular plate.

[0061] Positioning the annular plate at 308 may include locking the annular plate and the socket together by engaging a plurality of first stepped grooves (e.g., a plurality of first stepped grooves 97) of the annular plate with a plurality of first socket grooves (e.g., a plurality of first socket grooves 72) of the socket. Similarly, a plurality of second stepped grooves (e.g., a plurality of second stepped grooves 98) of the annular plate may engage a plurality of second socket grooves (e.g., a plurality of second socket grooves 74) of the socket. When the annular plate is engaged with the socket, the stepped grooves of the annular plate and / or the socket grooves of the socket may be deformed by the pressure of the annular plate on the socket, which may be used to lock the two structures together. Additionally or alternatively, the annular plate and the socket may be configured such that self-diffusion occurs between them to connect the annular plate and the socket together. Generally, when the annular plate is positioned at 308, it is placed slowly enough to limit and / or substantially avoid uneven destruction of the resin in the first laminate of the composite material below the annular plate.

[0062] The method 300 also includes inserting a torque screw (e.g., torque screw 80) of the fastener system into the socket at 310. In some examples, inserting the torque screw at 310 expands the socket as the torque screw presses outward against the receiving surface of the socket. Inserting the torque screw at 310 may include driving the torque screw into the socket so that the torque screw induces a deforming torque in the socket. Additionally or alternatively, inserting the torque screw at 310 may induce a deforming torque in a retainer and / or annular plate of the fastener system. The torque screw may be inserted from the outside of the fastener system at 310, such as from the outer surface of the first laminate of the composite material (e.g., the first outer surface 68). Various steps of the method 300, such as positioning the fastener assembly at 304, positioning the annular plate at 308, and / or inserting the torque screw at 310, may include cleaning and / or smoothing one or more surfaces of the fastener system to a sufficient degree to promote self-diffusion between the respective engaging surfaces. For example, such steps may include cleaning and / or smoothing the first engagement surface of the torque screw, the second engagement surface of the torque screw, the first interior receiving surface of the socket, and / or the second interior receiving surface of the socket.

[0063] Once the collar plate is positioned at 308 and the torque screw is inserted at 310, an external laminate (e.g., second laminate 54) of the composite material may be applied at 312. The external laminate is typically applied at 312 so that the external laminate covers the collar plate of the fastener system, thereby enclosing or embedding the collar plate between the external laminate of the composite material and the internal laminate of the composite material. Applying the external laminate at 312 may also include covering at least a portion of the intermediate laminate with the external laminate. In some methods, the entire intermediate laminate may be covered by the external laminate, while in other instances, a portion of the intermediate laminate may extend beyond the edge of the external laminate. In some methods, the collar plate may be encapsulated only between the internal and external laminates of the composite material without further including the intermediate laminate.

[0064] Some methods 300 include securing a part to a composite structure (the composite structure being comprised of a first laminate, an intermediate laminate, and / or an outer laminate of a composite material) at 314. For example, securing the part to the composite structure at 314 may include securing the part to a structural connector of a fastener system, which may be performed prior to positioning the fastener assembly at 304 or at any other stage of the method 300, such as after applying the outer laminate at 312. In some examples, securing the part to the composite structure at 314 may be performed prior to applying the outer laminate at 312 and / or prior to applying the intermediate laminate at 306. In some methods 300, securing the part to the composite structure at 314 includes using a tool to hold the part in place until after applying the outer laminate at 312. Securing the part to the composite structure at 314 may include coupling the part to the structural connector from an interior region of the composite structure, such as by accessing the structural connector adjacent to a first interior surface of the first laminate of the composite material. Then, an outer laminate of composite material applied at 312 may form an outer region of the composite structure. In this manner, method 300 generally includes coupling a part to a composite structure while applying a laminate (eg, an aircraft skin).

[0065] The method 300 may include heating the composite structure and the fastener system and parts coupled thereto at 316. Such heating may be performed at 316 to cure the inner laminate of the composite material, the middle laminate of the composite material, and / or the outer laminate of the composite material. In some examples, heating the composite structure at 316 may cause the parts to relax because one or more parts have been installed in or on the composite structure prior to curing the composite structure. In one specific example, heating the composite structure at 316 includes placing the composite structure (and any parts coupled thereto via one or more fastener systems of the present disclosure) in an oven or autoclave and heating the composite structure to a temperature sufficient to cure the composite structure. For example, heating the composite structure at 316 may include heating the composite structure to a temperature of at least 100°F, at least 150°F, at least 200°F, at least 250°F, at least 300°F, at least 350°F, at least 400°F, at least 450°F, at least 500°F, at least 550°F, and / or at least 600°F for a time sufficient to cure the laminate (panel skin) of the composite structure. In some examples, some or all of the steps of method 300 may be automated. For example, once one or more fastener assemblies are positioned relative to the composite structure at 304, one or more parts may be secured to the composite structure using automated techniques at 314.

[0066] Illustrative, non-exclusive examples of inventive subject matter according to the present disclosure are described in the following enumerated paragraphs:

[0067] A1. A fastener system for coupling a part to a composite structure, the fastener system comprising:

[0068] a socket configured to be at least partially embedded within the composite structure;

[0069] a torque screw configured to be at least partially received in the socket, wherein the torque screw is sized and shaped relative to the socket such that when pressed into the receiving portion, the receiving pin expands the receiving portion of the socket; and

[0070] A collar plate configured to be embedded within a composite structure and configured to distribute force from a torque screw being pressed into a receiving portion, wherein the fastener system is configured to engage a part and a composite structure to couple the part to the composite structure.

[0071] A2. The fastener system of paragraph A1, wherein the ring plate includes an opening configured to receive the socket therein.

[0072] A3. The fastener system of any of paragraphs A1-A2, wherein the torque screw is configured to expand the receiving portion of the socket against the annular plate when the torque screw is inserted into the receiving portion of the socket.

[0073] A4. A fastener system according to any of paragraphs A1-A3, wherein the opening of the ring plate includes a plurality of first stepped grooves and a plurality of second stepped grooves, wherein the plurality of first stepped grooves are positioned opposite to the plurality of second stepped grooves.

[0074] A5. The fastener system of paragraph A4, wherein the plurality of first stepped grooves and the plurality of second stepped grooves are configured to plastically deform when the torque screw is inserted into the receiving portion of the socket.

[0075] A6. A fastener system according to any of paragraphs A1-A5, wherein the ring plate includes a lower ring plate surface and an upper ring plate surface, wherein the upper ring plate surface is opposite to the lower ring plate surface, and wherein the opening extends from the upper ring plate surface to the lower ring plate surface so that the height of the opening is equal to the thickness of the ring plate.

[0076] A7. A fastener system according to any of paragraphs A1-A6, wherein the plurality of first stepped grooves of the ring plate are configured to engage with a plurality of first socket grooves of the socket, and wherein the plurality of second stepped grooves of the ring plate are configured to engage with a plurality of second socket grooves of the socket.

[0077] A8. A fastener system according to any of paragraphs A1-A7, wherein a plurality of first stepped grooves of the ring plate are formed on a first inclined surface of the opening of the ring plate, wherein the first inclined surface is not perpendicular to the upper ring plate surface and the lower ring plate surface of the ring plate, and wherein a plurality of second stepped grooves of the ring plate are formed on a second inclined surface of the opening of the ring plate, wherein the second inclined surface is not perpendicular to the upper ring plate surface and the lower ring plate surface.

[0078] A9. A fastener system as described in any of paragraphs A1-A8, wherein the size and shape of the ring plate are designed to adequately distribute loads within the composite structure to avoid damage to the parts when the torque screw is inserted into the socket.

[0079] A10. The fastener system of any of paragraphs A1-A9, wherein the opening of the ring plate is sized and shaped to fit over a first elongated groove surface of the socket and a second elongated groove surface of the socket.

[0080] A11. The fastener system of any of paragraphs A1-A10, wherein the socket comprises a first plurality of socket grooves and a second plurality of socket grooves, wherein the first plurality of socket grooves and the second plurality of socket grooves are configured to engage the ring plate.

[0081] A12. A fastener system according to any of paragraphs A1-A11, wherein the socket is configured to expand so that when a torque screw is inserted into the socket, it deforms the following elements: a plurality of first stepped grooves of the ring plate, a plurality of second stepped grooves of the ring plate, a plurality of first socket grooves of the socket and / or a plurality of second socket grooves of the socket.

[0082] A13. The fastener system of any of paragraphs A1-A12, wherein expansion and deformation of the socket produced by insertion of the torque screw forms a locking engagement between the socket and the ring plate.

[0083] A14. The fastener system of any of paragraphs A1-A13, wherein the socket includes a flex region configured to allow movement of the socket sufficient to allow the ring plate to be positioned on the socket.

[0084] A15. The fastener system of any of paragraphs A1-A14, wherein the socket comprises:

[0085] The first elongated groove surface includes a plurality of first socket grooves;

[0086] The second elongated groove surface includes a plurality of second socket grooves;

[0087] a receiving portion for receiving a torque screw, wherein the receiving portion is defined by a first interior receiving surface and a second interior receiving surface;

[0088] a flex region between the first inner receiving surface and the second inner receiving surface, wherein the flex region is configured to flex and / or compress such that the first elongated groove surface and the second elongated groove surface are forced closer together when the ring plate is inserted into the socket, and wherein the flex region is configured to allow the receiving portion to expand such that the first elongated groove surface and the second elongated groove surface move away from each other when the torque screw is inserted into the receiving portion.

[0089] A16. The fastener system of paragraph A15, wherein at least a portion of the first interior receiving surface is knurled.

[0090] A17. The fastener system of any of paragraphs A15-A16, wherein at least a portion of the second interior receiving surface is knurled.

[0091] A18. The fastener system of any of paragraphs A15-A17, wherein at least a portion of the first interior receiving surface is smooth.

[0092] A19. The fastener system of any of paragraphs A15-A18, wherein at least a portion of the second interior receiving surface is smooth.

[0093] A20. A fastener system according to any of paragraphs A1-A19, wherein the socket further comprises a first retainer receiving recess and a second retainer receiving recess positioned relative to each other, wherein the socket is configured to receive the retainer of the fastener system in the first retainer receiving recess and the second retainer receiving recess receiving portions.

[0094] A21. A fastener system as described in any of paragraphs A1-A20, wherein the socket also includes a narrow slot-shaped opening, and the lower portion of the torque screw is configured to be inserted through the narrow slot-shaped opening.

[0095] A22. The fastener system of paragraph A21, wherein the slot-shaped opening extends between the flexure zone and the second flexure zone.

[0096] A23. A fastener system according to any of paragraphs A1-A22, wherein the socket further includes a first extrusion surface and a second extrusion surface, wherein when the torque screw is positioned in the socket, the socket is configured to receive a lower portion of the torque screw between the first extrusion surface and the second extrusion surface.

[0097] A24. The fastener system of paragraph A23, wherein a lower portion of the torque screw is pressed outwardly on the first and second pressing surfaces when the torque screw is positioned within the socket.

[0098] A25. A fastener system as described in any of paragraphs A23-A24, wherein the retainer of the fastener system is pressed inwardly on the first and second extrusion surfaces when the retainer is positioned on the socket.

[0099] A26. The fastener system of any of paragraphs A1-A25, wherein the torque screw is configured to apply force to an upper portion of the socket and a lower portion of the socket.

[0100] A27. A fastener system as described in paragraph A26, wherein the upper portion of the socket includes a first elongated groove surface and a second elongated groove surface, and wherein the lower portion of the socket includes a first extrusion surface and a second extrusion surface.

[0101] A28. A fastener system according to any of paragraphs A1-A27, wherein the torque screw includes a wedge-shaped portion having a first engagement surface and a second engagement surface, wherein when the torque screw is positioned in the socket, the first engagement surface and the second engagement surface are configured to engage the socket.

[0102] A29. A fastener system according to paragraph A28, wherein at least a portion of the first engagement surface is knurled and / or wherein at least a portion of the second engagement surface is knurled.

[0103] A30. A fastener system according to paragraph A28 or A29, wherein the wedge-shaped portion is configured to be received in a receiving portion of the socket so that the first engaging surface engages a first inner receiving surface of the socket and so that the second engaging surface engages a second inner receiving surface of the socket.

[0104] A31. A fastener system as described in any of paragraphs A1-A30, wherein the torque screw includes a lower portion integrally formed with a wedge-shaped portion.

[0105] A32. A fastener system according to any of paragraphs A1-A31, wherein the lower portion of the torque screw is configured to extend through a narrow slot-shaped opening formed in the socket, thereby clamping the lower portion by the first extrusion surface and the second extrusion surface of the socket.

[0106] A33. The fastener system of any of paragraphs A1-A32, wherein the fastener system includes a retainer.

[0107] A34. A fastener system as described in paragraph A33, wherein the retainer is configured to have a sliding fit with the first retainer receiving recess of the socket and the second retainer receiving recess of the socket.

[0108] A34.1. A fastener system as described in paragraph A33 or A34, wherein the retainer is configured to constrain the socket.

[0109] A34.2. The fastener system of any of paragraphs A33-A34.1, wherein the retainer is configured to urge the socket around the torque screw.

[0110] A35. The fastener system of any of paragraphs A34-A34.2, wherein the retainer comprises a first elongated portion configured to engage a first retainer receiving recess.

[0111] A36. The fastener system of paragraph A35, wherein the retainer includes a second elongated portion configured to engage the second retainer receiving recess.

[0112] A37. A fastener system as described in paragraph A36, wherein the first slender portion is substantially parallel to the second slender portion.

[0113] A38. A fastener system as described in paragraphs A36 or A37, wherein the first slender portion is spaced apart from the second slender portion by a distance at least equal to and optionally greater than a width of a lower portion of the torque screw.

[0114] A39. A fastener system according to any of paragraphs A36-A38, wherein the retainer includes a vertical member connecting the first slender portion to the second slender portion, wherein the vertical member is substantially perpendicular to the first slender portion and / or the second slender portion so that the retainer forms a straight U-shape.

[0115] A40. A fastener system as described in any of paragraphs A34-A39, wherein the retainer includes at least one fastener extending through the first slender portion and the second slender portion, wherein once the retainer is positioned on the socket, the at least one fastener is configured to tighten the retainer around the socket.

[0116] A41. A fastener system as described in paragraph A40, wherein the at least one fastener is configured to extend when the torque screw is pressed outwardly on the socket.

[0117] A42. The fastener system of any of paragraphs A1-A41, wherein the receptacle is further configured to receive a structural connector.

[0118] A42.1. A fastener system as described in paragraph A41, wherein the structural connector includes a shear strap, a fitting, a bracket, an interrib, and / or any other structural connector configured to engage the part and the composite structure.

[0119] A43. The fastener system of any of paragraphs A1-A42, further comprising a structural connector, wherein the structural connector is configured to engage the socket.

[0120] A44. The fastener system of paragraph A43, wherein the structural connector includes a slot configured to receive the socket therethrough.

[0121] A44.1. The fastener system of paragraphs A43 or A44, wherein the structural connector includes a shear strap, and wherein the slot includes a shear strap slot configured to receive a socket therethrough.

[0122] A45. A fastener system as described in any of paragraphs A42-A44.1, wherein the structural connector is configured to engage the socket such that at least a portion of the structural connector engages the socket between the retainer and the ring plate.

[0123] A46. A fastener system as described in any of paragraphs A42-A45, wherein the socket includes a first outer wall and a second outer wall, and wherein the structural connector contacts the first outer wall and the second outer wall when the structural connector is secured to the socket.

[0124] A47. A fastener system as described in any of paragraphs A1-A46, wherein the torque screw and the socket are both formed from a first metal.

[0125] A48. The fastener system of any of paragraphs A1-A47, wherein the part comprises a frame, a fitting, and / or a bracket.

[0126] A49. The fastener system of any of paragraphs A1-A48, wherein the composite structure comprises a carbon fiber skin of an aircraft fuselage.

[0127] A50. The fastener system of any of paragraphs A1-A49, wherein the fastener system directly couples a part to a composite structure.

[0128] A51. The fastener system of any of paragraphs A1-A50, wherein the fastener system couples the part to the composite structure via a structural connector.

[0129] A52. A fastener system as described in any of paragraphs A1-A51, wherein the torque screw and the socket are joined together via self-diffusion, friction connection and / or deformation.

[0130] A53. The fastener system of any of paragraphs A1-A52, wherein the ring plate and the socket are joined together via self-diffusion, friction connection, and / or deformation.

[0131] B1. A component comprising:

[0132] A fastener system for coupling a part to a composite structure, wherein the fastener system is the fastener system described in any of paragraphs A1-A53;

[0133] a first laminate of the composite material; and

[0134] A second laminate of composite material wherein the collar plate of the fastener system is located between the first laminate of composite material and the second laminate of composite material.

[0135] B2. The assembly of paragraph B1, further comprising a structural connector, at least a portion of which is positioned adjacent to the first laminate of the composite material.

[0136] B3. The assembly of paragraph B2, further comprising a retainer for the fastener system, wherein a portion of the structural connector is sandwiched between the retainer and the inner surface of the first laminate of the composite material.

[0137] B4. An assembly as described in any of paragraphs B1-B3, wherein the first laminate of the composite material includes an outer surface opposite the inner surface, wherein the first laminate of the composite material is oriented so that the outer surface faces the second laminate of the composite material.

[0138] B5. The assembly of any of paragraphs B1-B4, wherein the first laminate of composite materials and / or the second laminate of composite materials comprises polymer-reinforced carbon fibers.

[0139] B6. The assembly of any of paragraphs B1-B5, wherein the second laminate of the composite material is an outer skin of an aircraft fuselage.

[0140] B7. The assembly of any of paragraphs B1-B6, wherein the first laminate of the composite material is an inner skin of an aircraft fuselage.

[0141] B8. The assembly of any of paragraphs B1-B7, further comprising an intermediate laminate of composite material positioned between the first laminate of composite material and the second laminate of composite material.

[0142] B9. An assembly according to paragraph B8, wherein the intermediate laminate of the composite material has a laminate thickness substantially equal to the plate thickness of the collar plate.

[0143] B10. The assembly of any of paragraphs B1-B9, wherein the first laminate of composite material includes a first plurality of layers of composite material.

[0144] B11. The assembly of any of paragraphs B1-B10, wherein the second laminate of composite material includes a second plurality of layers of composite material.

[0145] B12. The assembly of any of paragraphs B1-B11, wherein the intermediate laminate of composite material includes a third plurality of layers of composite material.

[0146] B13. The assembly of any of paragraphs B1-B12, wherein the first laminate of composite material, the second laminate of composite material, and / or the intermediate laminate of composite material together form a composite structure.

[0147] C1. A method of assembling a fastener assembly for coupling a part to a composite structure, the method comprising:

[0148] positioning a retainer of the fastener assembly over a receptacle of the fastener assembly; and

[0149] A structural connector of a fastener assembly is positioned on the socket, wherein the fastener assembly is configured to couple the part to the composite structure via the structural connector.

[0150] C2. The method of paragraph C1, wherein the fastener assembly is a fastener system of any of paragraphs A1-A53.

[0151] C3. The method of any of paragraphs C1-C2, wherein positioning the retainer includes sliding the retainer into a first retainer receiving recess of the socket and into a second retainer receiving recess of the socket.

[0152] C4. A method as described in any of paragraphs C1-C3, wherein positioning the retainer includes installing at least one fastener on the retainer to fasten and / or secure the retainer around the socket.

[0153] C5. A method as described in any of paragraphs C1-C4, wherein positioning the retainer is performed after positioning the structural connector.

[0154] C6. The method of any of paragraphs C1-C5, further comprising forming a slot-shaped opening in the structural connector, wherein the slot-shaped opening is sized and shaped to fit over a portion of the socket to secure the structural connector to the socket.

[0155] C7. A method according to any of paragraphs C1-C6, wherein positioning the structural connector includes compressing and plastically deforming a portion of the socket.

[0156] C8. The method of paragraph C7, wherein positioning the structural connector includes allowing the portion of the receptacle to return to its unstressed state, thereby securing the structural connector to the receptacle.

[0157] C9. The method of any of paragraphs C1-C8, wherein positioning the structural connector includes contacting the retainer with the structural connector.

[0158] D1. A method of installing a fastener system for connecting a part to a composite structure, the method comprising:

[0159] The fastener assembly is positioned relative to an inner laminate of a composite material such that a socket of the fastener assembly is at least partially inserted through a receiving hole of the inner laminate of the composite material and such that the inner laminate of the composite material engages a structural connector of the structural fastener assembly, wherein the inner laminate of the composite material forms a portion of a composite structure.

[0160] D1.1. The method of paragraph D1, further comprising forming an inner laminate of composite material and forming a receiving hole therethrough.

[0161] D2. The method of paragraph D1 or D1.1, wherein the fastener assembly is the fastener system of any of paragraphs A1-A53.

[0162] D3. The method of any of paragraphs D1-D2, wherein the fastener assembly is assembled according to the method of any of paragraphs C1-C9 before positioning the fastener assembly.

[0163] D4. The method of any of paragraphs D1-D3, wherein positioning the fastener assembly includes positioning the fastener assembly such that a portion of the structural connector is located between an inner laminate of the composite material and a retainer of the fastener assembly.

[0164] D5. The method of any of paragraphs D1-D4, wherein the inner laminate of composite material includes a first plurality of layers of composite material.

[0165] D6. A method as described in any of paragraphs D1-D5, wherein the inner laminate of the composite material includes a first outer surface and a first inner surface, wherein the receiving hole extends from the first outer surface to the first inner surface, and wherein the first inner surface engages the structural connector.

[0166] D7. The method described in any of paragraphs D1-D6 further includes securing an intermediate laminate of the composite material to a first upper surface of an inner laminate of the composite material, wherein the intermediate laminate of the composite material includes a pocket-shaped area configured to receive at least a portion of the socket passing therethrough, and wherein the pocket-shaped area is further configured to receive a loop plate of a fastener system.

[0167] D8. The method of any of paragraphs D1-D7, further comprising positioning an annular plate of the fastener system onto the socket such that a lower plate surface of the annular plate engages the first upper surface of the inner laminate of the composite material.

[0168] D9. The method of paragraph D8, wherein positioning the grommet plate includes positioning the grommet plate in a pocket region of an intermediate laminate of the composite material.

[0169] D9.1. A method according to paragraph D8 or D9, wherein the positioning ring plate includes locking the ring plate and the socket together by engaging a plurality of first stepped grooves of the ring plate, a plurality of second stepped grooves of the ring plate, a plurality of first socket grooves of the socket, and a plurality of second socket grooves of the socket.

[0170] D9.2. A method according to any of paragraphs D8-D9.1, wherein positioning the annular plate includes engaging the annular plate and the socket so that self-diffusion occurs therebetween.

[0171] D10. The method of any of paragraphs D8-D9.2, wherein positioning the grommet plate includes placing the grommet plate slowly enough to substantially avoid uneven disruption of resin applied to an inner laminate of the composite material.

[0172] D11. The method of any of paragraphs D1-D10, further comprising inserting a torque screw of the fastener system into the socket.

[0173] D12. The method of paragraph D11, wherein inserting the torque screw includes expanding the socket with the torque screw as the torque screw is inserted.

[0174] D12.1. The method of paragraph D11 or D12, wherein inserting the torque screw comprises driving the torque screw into a socket, thereby inducing a deforming torque in the socket, in a retainer of the fastener assembly, and / or in a ring plate of the fastener system.

[0175] D12.2. The method of any of paragraphs D11-D12.1, wherein inserting the torque screw includes inserting the torque screw from a first outer surface of an inner laminate of the composite material.

[0176] D13. The method of any of paragraphs D1-D12.2, further comprising applying an outer laminate of composite material.

[0177] D14. The method of paragraph D13, wherein applying the composite outer laminate includes covering a collar panel of the fastener system with the composite outer laminate.

[0178] D15. A method according to paragraph D13 or D14, wherein applying the outer laminate of the composite material includes applying the outer laminate of the composite material to the middle laminate of the composite material so that at least a portion of the middle laminate of the composite material is covered by the outer laminate of the composite material.

[0179] D16. The method of any of paragraphs D13-D15, wherein applying the outer laminate of composite material includes embedding an eyelet panel of the fastener system between the outer laminate of composite material and the inner laminate of composite material.

[0180] D17. The method of any of paragraphs D1-D16, wherein the outer laminate of composite material includes a second plurality of layers of composite material.

[0181] D18. The method of any of paragraphs D1-D17, wherein the intermediate laminate of composite material includes a third plurality of layers of composite material.

[0182] D19. The method of any of paragraphs D1-D18, wherein the inner laminate of the composite material, the outer laminate of the composite material, and / or the middle laminate of the composite material together form a composite structure.

[0183] D20. The method of any of paragraphs D1-D19, further comprising securing the part to a structural connector to couple the part to the composite structure.

[0184] D20.1. The method of paragraph D20, wherein securing the part is performed before positioning the fastener assembly.

[0185] D20.2. The method of paragraph D20 or D20.1, wherein securing the part is performed before adding and / or applying an outer laminate of composite material and an intermediate laminate of composite material to an inner laminate of composite material.

[0186] D20.3. The method of any of paragraphs D20-D20.2, further comprising holding the part in place with a tool until after the outer laminate of composite material and the middle laminate of composite material are added and / or applied.

[0187] D21. A method according to any of paragraphs D1-D20.3, wherein the parts include frames, accessories and / or brackets.

[0188] D22. The method of any of paragraphs D1-D21, wherein the composite structure comprises a carbon fiber skin of an aircraft fuselage.

[0189] D23. The method of any of paragraphs D1-D22, further comprising selecting a thickness of the flexure region of the socket to allow insertion of a torque screw and / or an annular plate of a fastener system.

[0190] D24. The method of any of paragraphs D1-D23, further comprising cleaning and / or smoothing one or more surfaces of the fastener system to a degree sufficient for self-diffusion.

[0191] D25. A method according to paragraph D24, wherein one or more surfaces of the fastener system include a first engaging surface of the torque screw, a second engaging surface of the torque screw, a first internal receiving surface of the socket and / or a second internal receiving surface of the socket.

[0192] D26. The method of any of paragraphs D1-D25, wherein the fastener system comprises a fastener assembly, a ring plate, and a torque screw.

[0193] D27. The method of any of paragraphs D1-D26, wherein the method of installing a fastener system for coupling a part to a composite structure is a method of forming an aircraft fuselage, wherein the composite structure is an aircraft fuselage.

[0194] D28. A method according to any of paragraphs D1-D27, wherein positioning the fastener component relative to the internal laminate of the composite material includes positioning the fastener component via a first inner surface of the internal laminate of the composite material, wherein the first inner surface forms an interior region of the composite structure.

[0195] D29. The method of paragraph D28, further comprising coupling the part to the structural connector from an interior region of the composite structure.

[0196] D30. The method of any of paragraphs D1-D29, wherein an outer surface of the outer laminate forms an outer region of the composite structure.

[0197] D31. The method of any of paragraphs D1-D30, wherein positioning the fastener assembly is performed prior to adding and / or applying the composite material outer laminate and the composite material middle laminate.

[0198] D32. The method of any of paragraphs D1-D31, further comprising heating the composite structure and the fastener system to cure the inner laminate of the composite material, the outer laminate of the composite material, and / or the middle laminate of the composite material.

[0199] D33. The method of paragraph D32, wherein the heating causes the part to relax.

[0200] D34. A method according to any of paragraphs D1-D33, wherein positioning the fastener assembly includes installing the retainer with the socket.

[0201] E1. An aircraft comprising a fastener system as described in any of paragraphs A1-A53 and / or an assembly as described in any of paragraphs B1-B13.

[0202] F1. Using a fastener system as described in any of paragraphs A1-A53 to couple a part to a composite structure.

[0203] F2. Using a fastener system as described in any of paragraphs A1-A53 to couple a frame to an aircraft fuselage.

[0204] F3. Manufacturing an aircraft using an assembly of components according to any of paragraphs B1-B13.

[0205] As used herein, the terms "selective" and "selectively" when used in connection with an action, motion, configuration, or other activity that modifies one or more components or characteristics of a device, mean that the particular action, motion, configuration, or other activity is the direct or indirect result of a user operating on an aspect or one or more components of the device.

[0206] As used herein, the terms "adapted to" and "configured to" refer to elements, components, or other subjects that are designed and / or intended to perform a given function. Therefore, the use of the terms "adapted to" and "configured to" should not be interpreted as meaning that a given element, component, or other subject is merely "capable of" performing a given function, but rather that the element, component, and / or other subject is specifically selected, created, implemented, utilized, programmed, and / or designed to perform the function. It is also within the scope of the present disclosure that elements, components, and / or other listed subjects that are listed as being suitable for performing a particular function may additionally or alternatively be described as being configured to perform the function, and vice versa. Similarly, a subject listed as being configured to perform a particular function may additionally or alternatively be described as being operable to perform the function.

[0207] As used herein, the phrase "at least one" in reference to a list of one or more entities should be understood to refer to at least one entity selected from any one or more entities in the list of entities, but does not necessarily include at least one of each entity explicitly listed in the list of entities, and does not exclude any combination of entities in the list of entities. This definition also allows for the optional presence of entities in addition to the entities specifically identified within the list of entities to which the phrase "at least one" refers, whether related or unrelated to those specifically identified entities. Thus, as a non-limiting example, "at least one of A and B" (or equivalently, "at least one of A or B", or equivalently "at least one of A and / or B") may refer to at least one, optionally including more than one A, with no B (and optionally including entities other than B) in one embodiment; to at least one, optionally including more than one B, with no A (and optionally including entities other than A) in another embodiment; and to at least one, optionally including more than one A, and at least one, optionally including more than one B (and optionally including other entities) in yet another embodiment. In other words, the phrases "at least one", "one or more", and "and / or", which are connectors and separators in operation, are open-ended expressions. For example, each of the expressions "at least one of A, B, and C", "at least one of A, B or C", "one or more of A, B and C", "one or more of A, B or C", and "A, B and / or C" may mean A alone, B alone, C alone, A and B together, A and C together, B and C together, A, B and C together, and optionally any of the foregoing in combination with at least one other entity.

[0208] Not all devices and methods according to the present disclosure require the steps of the various elements and methods of the devices disclosed herein, and the present disclosure includes all novel and non-obvious combinations and sub-combinations of the various elements and steps disclosed herein. In addition, one or more of the various elements and steps disclosed herein may define an independent inventive subject matter, which is independent of and different from the entirety of the disclosed device or method. Therefore, such an inventive subject matter is not required to be associated with the specific device and method explicitly disclosed herein, and such an inventive subject matter may find utility in devices and / or methods not explicitly disclosed herein.

[0209] As used herein, the phrase "for example", the phrase "as an example" and / or simply the term "example", when used with reference to one or more components, features, details, structures, implementations and / or methods according to the present disclosure, is intended to convey that the described components, features, details, structures, implementations and / or methods are illustrative, non-exclusive examples of components, features, details, structures, implementations and / or methods according to the present disclosure. Therefore, the described components, features, details, structures, implementations and / or methods are not intended to be limiting, required or exclusive / exhaustive; and other components, features, details, structures, implementations and / or methods that are similar and / or equivalent in structure and / or function are also within the scope of the present disclosure.

Claims

1. A fastener system for coupling a part (40) to a composite structure (42), the fastener system comprising: a socket (34) configured to be at least partially embedded in the composite structure (42), wherein the socket (34) includes a receiving portion (44) configured to receive at least a portion of a torque screw (36); a structural connector (60) configured to engage the socket (34) and the component; the torque screw (36), wherein the torque screw (36) is configured to be at least partially received within the socket (34), wherein the torque screw (36) is sized and shaped relative to the socket (34) such that when pressed into the receiving portion (44), the torque screw causes the receiving portion (44) of the socket (34) to expand; and a collar plate (38) configured to be embedded within the composite structure (42) and configured to distribute force from the torque screw (36) being pressed into the receiving portion (44), wherein the fastener system is configured to engage the part and the composite structure (42) such that the fastener system couples the part (40) to the composite structure (42).

2. The fastener system of claim 1, wherein: The annular plate (38) includes an opening (67) configured to receive the socket (34) therethrough, and wherein the torque screw (36) is configured to expand the receiving portion (44) of the socket (34) against the annular plate (38) when the torque screw (36) is inserted into the receiving portion (44) of the socket (34).

3. The fastener system of claim 2, wherein: The opening (67) of the annular plate (38) includes a plurality of first stepped grooves (97) and a plurality of second stepped grooves (98), wherein the plurality of first stepped grooves (97) are positioned relative to the plurality of second stepped grooves (98), and wherein the plurality of first stepped grooves (97) and the plurality of second stepped grooves (98) are configured to plastically deform when the torque screw (36) is inserted into the receiving portion (44) of the socket (34).

4. The fastener system of claim 3, wherein: The plurality of first stepped grooves (97) of the ring plate (38) are configured to engage with the plurality of first socket grooves of the socket (34), and wherein the plurality of second stepped grooves (98) of the ring plate (38) are configured to engage with the plurality of second socket grooves of the socket (34).

5. The fastener system according to any one of claims 1 to 4, wherein: The receiving portion (44) of the socket (34) is defined by a first inner receiving surface and a second inner receiving surface, and wherein the socket (34) comprises: a first elongated grooved surface including a plurality of first socket grooves; a second elongated grooved surface including a plurality of second socket grooves; and a flex region located between the first inner receiving surface and the second inner receiving surface, wherein the flex region is configured to flex when the ring plate (38) is inserted on the socket (34) so ​​that the first elongated groove surface and the second elongated groove surface are forced close together, and wherein the flex region is configured to allow the receiving portion (44) to expand so that the first elongated groove surface and the second elongated groove surface move away from each other when the torque screw (36) is inserted into the receiving portion (44).

6. The fastener system of claim 5, wherein: The flexure region includes a first flexure region and a second flexure region, wherein the socket (34) further includes a slot-shaped opening (67), a lower portion of the torque screw (36) is configured to be inserted through the slot-shaped opening (67), and wherein the slot-shaped opening extends between the first flexure region and the second flexure region.

7. The fastener system of claim 6, wherein: The socket (34) also includes a first pressing surface and a second pressing surface, wherein the socket (34) is configured to receive the lower portion of the torque screw (36) between the first pressing surface and the second pressing surface when the torque screw (36) is located in the socket (34).

8. The fastener system of claim 7, wherein: The fastener system includes a retainer configured to constrain the socket (34), wherein the socket (34) further includes a first retainer receiving recess and a second retainer receiving recess positioned relative to each other, wherein the socket (34) is configured to receive the retainer in the first retainer receiving recess and the second retainer receiving recess, wherein the retainer includes a first slender portion, the first slender portion is configured to engage with the first retainer receiving recess, and wherein the retainer also includes a second slender portion, the second slender portion is configured to engage with the second retainer receiving recess.

9. The fastener system of claim 8, wherein: The retainer of the fastener system is pressed inwardly on the first and second pressing surfaces when the retainer is positioned on the socket (34).

10. The fastener system of claim 5, wherein: The torque screw (36) includes a wedge-shaped portion having a first engagement surface and a second engagement surface, wherein the first engagement surface and the second engagement surface are configured to engage with the socket (34) when the torque screw (36) is positioned in the socket (34), wherein the wedge-shaped portion is configured to be received in the receiving portion (44) of the socket (34) so ​​that the first engagement surface engages with the first internal receiving surface of the socket (34) via one or more selected from the group consisting of self-diffusion, friction connection and deformation and the second engagement surface engages with the second internal receiving surface of the socket (34) via one or more selected from the group consisting of self-diffusion, friction connection and deformation.

11. The fastener system of any one of claims 1 to 4, wherein: The structural connector (60) includes a slot configured to receive a socket (34) therethrough, wherein the socket (34) includes a first outer wall and a second outer wall, and wherein when the structural connector (60) is secured to the socket (34), the structural connector (60) contacts the first outer wall and the second outer wall.

12. The fastener system according to any one of claims 1 to 4, wherein: The part (40) comprises a frame for an aircraft fuselage, and wherein the composite structure (42) comprises a skin of the aircraft fuselage.

13. A component comprising: The fastener system according to claim 1; a first laminate of the composite material; and A second laminate of a composite material, wherein the collar plate (38) of the fastener system is located between the first laminate of the composite material and the second laminate of the composite material, and wherein at least a portion of the structural connector (60) of the fastener system is positioned adjacent to the first laminate of the composite material.

14. The assembly of claim 13 further comprising an intermediate laminate of composite material located between the first laminate of composite material and the second laminate of composite material, wherein The laminate thickness of the intermediate laminate of the composite material is equal to the plate thickness of the ring plate (38).

15. A method of assembling a fastener assembly for coupling a part (40) to a composite structure (42), the method comprising: The fastener assembly is provided, wherein the fastener assembly comprises: A socket (34) is configured to be at least partially embedded in the composite structure (42), wherein the socket (34) includes: a receiving portion (44) configured to receive at least a portion of a torque screw (36); a first retainer receiving recess; and a second retainer receiving recess opposite to the first retainer receiving recess; a structural connector (60) configured to engage the socket (34) and the part (40); and a retainer configured to constrain the socket (34), wherein the socket (34) is configured to receive the retainer in the first retainer receiving recess and the second retainer receiving recess, wherein the retainer includes a first elongated portion configured to engage the first retainer receiving recess, wherein the retainer further includes a second elongated portion configured to engage the second retainer receiving recess; positioning the retainer on the socket (34) by sliding the retainer into the first retainer receiving recess and the second retainer receiving recess; and The structural connector (60) is positioned on the socket (34), wherein positioning the structural connector (60) includes compressing the socket (34), wherein the fastener assembly is configured to couple the part (40) to the composite structure (42) via the structural connector (60).

16. A method of installing a fastener system for coupling a part (40) to a composite structure (42), wherein: The fastener system includes a fastener assembly, a ring plate (38) and a torque screw (36), and the method includes: forming a first laminate of a composite material, wherein a receiving hole is formed through the first laminate; positioning the fastener assembly relative to the first laminate of the composite material such that a socket (34) of the fastener assembly is at least partially inserted through the receiving aperture and the first laminate of the composite material engages a structural connector (60) of the fastener assembly, wherein the socket (34) of the fastener assembly, the structural connector (60) and a retainer are assembled together prior to positioning the fastener assembly, wherein the first laminate of the composite material includes a first outer surface and a first inner surface, wherein the receiving aperture extends from the first outer surface to the first inner surface, and wherein the first inner surface engages the structural connector (60); securing an intermediate laminate of composite material to the first outer surface of the first laminate of composite material, wherein the intermediate laminate of composite material includes a pocket configured to receive at least a portion of the socket (34) therein, and wherein the pocket is further configured to receive the collar plate (38) of the fastener system; Positioning the annular plate (38) on the socket (34) and positioning the annular plate (38) in the pocket region of the middle laminate of the composite material such that the lower plate surface of the annular plate (38) engages the first outer surface of the first laminate of the composite material; inserting the torque screw (36) of the fastener system into the socket (34); and Applying an outer laminate of a composite material, the outer laminate covering the annular plate (38) and at least a portion of the intermediate laminate of the composite material, thereby embedding the annular plate (38) between the outer laminate of the composite material and the first laminate of the composite material, wherein the first laminate of the composite material, the intermediate laminate of the composite material and the outer laminate of the composite material together form the composite structure (42).

17. The method according to claim 16, wherein: Positioning the ring plate (38) includes locking the ring plate (38) and the socket (34) together by engaging a plurality of first stepped grooves (97) of the ring plate (38) with a plurality of first socket grooves of the socket (34) and engaging a plurality of second stepped grooves (98) of the ring plate (38) with a plurality of second socket grooves of the socket (34).

18. The method according to claim 16 or 17, wherein: Inserting the torque screw (36) includes the torque screw (36) expanding the socket (34) as the torque screw (36) is inserted.

19. The method of claim 16 or 17, further comprising securing the part (40) to the structural connector (60) to couple the part (40) to the composite structure (42), wherein: The part (40) comprises a frame of an aircraft fuselage, and wherein the composite structure (42) comprises a skin of the aircraft fuselage.

20. The method of claim 16 or 17, further comprising heating the composite structure (42) and the fastener system to cure the first laminate of composite material, the outer laminates of composite material, and the middle laminate of composite material.

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