Sealed fastening system

Abstract

The deformable fastening system includes a clamped component and a fastener including a bolt having a shaft portion and a head portion, the shaft portion extending along a longitudinal axis of the fastener, the head portion including at least one engaging portion and one or more protrusions formed on the at least one engaging portion on a surface thereof, the one or more protrusions being formed on the at least one engaging portion, typically adjacent to the shaft portion, and the one or more protrusions formed on the at least one engaging portion engage with a mating surface of the clamped component as the bolt is driven into the nut member to clamp the clamped component, thereby increasing an axial load during a tightening cycle and deforming the clamped component.

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application is a continuation-in-part of U.S. Patent Application No. 16 / 460,559, filed July 2, 2019, and U.S. Provisional Application No. 63 / 423,987, filed November 9, 2022, both of which are incorporated by reference in their entireties. [Background technology]

[0002] The present invention relates generally to a system for reducing the clamping force required to effectively install bolts, such as flow bolts, and to a fastening system having an improved sealing arrangement.

[0003] Fasteners such as mating screws and rivets may be used to mechanically join components at a joint, using complementary mating threads in the case of a screw, or deformed ends in the case of a rivet, to apply a compressive or clamping load to the components being joined, and a corresponding tensile load to the fastener.

[0004] When two or more materials are assembled together using one or more fasteners, the fasteners that clamp the materials together create a clamping load or force. The clamping force needs to be great enough to adequately secure the materials together, but the clamping force should not be so great that it damages the materials that it is fastening.

[0005] Torque wrenches are often used to tighten fasteners in an attempt to apply just the right amount of clamping force. Torque wrenches include a dial that provides a visual indication as to the amount of torque being applied. Other clamp load indicating devices, such as sealed liquids, are sometimes used in the industry to prevent the application of excessive clamping force.

[0006] Some applications require a flow bolt. A flow bolt is a bolt specifically configured to provide a seal at one or more locations and allow fluid to flow either through a through-hole formed through the bolt shaft or along a fluid flow path provided along the bolt shaft. For example, some flow bolts have one or more external flutes machined or otherwise formed on the threads. As a result of a flow bolt having one or more external flutes machined or otherwise formed on the threads, the flow bolt can typically be handled with a lower clamping force before the threads on either the bolt or the nut member become stripped. More specifically, the threads on the flow bolt and / or the nut member are susceptible to becoming stripped during tightening of the fastener in an attempt to achieve sufficient preload to obtain a proper seal. A standard flow bolt without one or more external flutes machined or otherwise formed on the threads also requires a lower clamping load due to the smaller cross-sectional area of ​​the bolt.

[0007] As shown in Figures 1A and 1B, one typical application for the flow bolt 10 is in connection with an automobile brake hose 12. More specifically, the flow bolt 10 is inserted through a bore 14 into a connector 16 at the end of the brake hose 12, such that one metal washer 20 is positioned between a head 22 of the flow bolt 10 and the connector 16 at the end of the brake hose 12, and another metal washer 24 is positioned between the connector 16 and a fastening member 26, such as a nut member, of the flow bolt 10. When the flow bolt 10 is then tightened, both washers 20, 24 are compressed, thereby forming a seal between the connector 16 and each of the washers 20, 24, as shown in Figures 2A and 2B. Because the washers 20, 24 must be compressed during installation of the flow bolt 10, copper is typically chosen as the material for the washers. Also, washers used in such applications are often referred to as "crush washers" because the washers are essentially compressed or crushed during installation.

[0008] Sufficient axial force must be applied to the flow bolt 10 to form a proper seal between the copper washers 20, 24 and the connector 16 on the end of the brake hose 12. In other words, the flow bolt 10 and nut member 26 must be tightened sufficiently so that the copper washers 20, 24 are pressed against the connector 16 with enough force to form a seal. However, the threads on the flow bolt 10 and / or nut member 26 may become stripped while achieving sufficient axial force to form this seal, especially if the bolt includes one or more external longitudinal grooves 28 spanning the threads. Summary of the Invention

[0009] It is an object of embodiments of the present invention to provide a deformable fastening system that can seal with a lower clamp load than is required to seal conventional fastening systems.

[0010] It is an object of embodiments of the present invention to provide a system that reduces the preload required to install fasteners.

[0011] Another object of an embodiment of the present invention is to provide a system for controlling the amount of axial force required to achieve a desired clamp load when a fastener, such as a washer and bolt combination, a bolt, or a flow bolt, is installed.

[0012] Another object of embodiments of the present invention is to reduce the clamping force range for a given torque, thereby requiring less preload to properly install the fastener.

[0013] It is yet another object of an embodiment of the present invention to provide a system that reduces the clamp load required to obtain a seal when installing a flow bolt, the clamp load reduction provided by the system being greater than or equal to the clamp load reduction that would result from either having one or more external flutes across the bolt threads, or simply the bolt being a flow bolt with a reduced cross-sectional area.

[0014] It is yet another object of an embodiment of the present invention to provide a system that reduces the crush area of ​​a deformable member.

[0015] It is yet another object of an embodiment of the present invention to provide a system that provides a deformable fastening system that includes a sealed clinch mechanism.

[0016] In an embodiment of the invention, a deformable fastening system includes a deformable member and a mating member that forms a seal with the deformable member, and the clamping load required for the deformable member to form a seal with the mating member is less than the clamping load required to seal a non-deformable member with a conventional mating member in a conventional fastening system.

[0017] In an embodiment of the invention, the deformable member comprises a fastener including at least one step with an inner portion having a first side and a second side opposite the first side, the inner portion being bounded by an inner maximum dimension, and at least one first outer portion being integrally formed with the first side of the inner portion and projecting outwardly from the first side of the inner portion to define a first outer surface, the first outer surface being bounded by a first outer maximum dimension that is smaller than the inner maximum dimension.

[0018] In an embodiment of the present invention, the first axial force applied to the fastener to reach the required axial force is less than the second axial force applied to conventional fasteners to seal the conventional fastening system.

[0019] In another embodiment of the invention, at least one outer portion has either a rectangular side profile or a first tapered portion defining a first tapered profile, and a first planar portion defining the first outer portion.

[0020] In an embodiment of the invention, the deformable member is a washer having a uniform intermediate portion that defines an inner portion.

[0021] In embodiments of the present invention, the washer has either at least one rectangular step or taper on each side of the inner portion of the washer. The at least one rectangular step or taper on the washer reduces the effective contact surface area when compared to conventional shapes. Conventional washers are circular with a hole in the center and flat on both the top and bottom. Unlike conventional washers, washers according to embodiments of the present invention provide either a stepped or tapered configuration, where both the top and bottom of the washer are either stepped or tapered, resulting in a reduced contact surface area, which in turn requires substantially less axial force to properly install the fastener.

[0022] In an embodiment of the invention, the washer has at least one second outer portion integrally formed with the uniform intermediate portion, the at least one second outer portion projecting outwardly from a second side of the uniform intermediate portion to define a second outer surface, the second outer surface being bounded by a second outer maximum dimension that is smaller than the inner maximum dimension.

[0023] In an embodiment of the invention, at least one outer portion of the washer has a first rectangular side profile.

[0024] In an embodiment of the invention, the at least one second outer portion of the washer has a second rectangular side profile.

[0025] In an embodiment of the invention, the at least one first outer portion of the washer has a first tapered portion defining a first tapered shape and a first planar portion defining a first outer surface.

[0026] In an embodiment of the invention, the at least one second outer portion of the washer has a second tapered portion defining a second tapered shape and a second planar portion defining a second outer surface.

[0027] In an embodiment of the invention, the engaging member includes a non-deforming fastener having at least one outer portion, the at least one outer portion of the non-deforming fastener contacting the deformable member to deform the deformable member.

[0028] In an embodiment of the invention, the non-deforming fastener is a bolt having a shaft and a head, the head having a lower surface including at least one step defining an outer portion, the at least one step engaging the deformable member to deform the deformable member and continue to deform the deformable member until the outer portion contacts the deformable member at a desired clamping load.

[0029] In an embodiment of the invention, the deformable member receives a bolt and may include a component to be clamped, such as a workpiece.

[0030] In another embodiment of the invention, the non-deforming fastener comprises a clinch fastener that forms a seal with a deformable member, the deformable member being a crimping or mating material.

[0031] In an embodiment of the invention, a clinch fastener includes a bolt having a shaft and a head, the head having a lower surface including at least one step defining at least one outer portion, the at least one step mating with a mating material to deform and clinch the mating material and form a seal with the mating material.

[0032] In an embodiment of the invention, the clinch fastener includes at least one retention groove into which a portion of the deformable mating material flows when the bolt is driven through the mating material.

[0033] In an embodiment of the invention, at least one step is not deformable and mates with the deformable member. In another embodiment of the invention, at least one step is deformable and forms a seal with the mate member.

[0034] In another embodiment of the invention, the bolt may be used in a system that also includes a nut member and a clamped component between the bolt and the nut member, the clamped component preferably being formed from a material that is softer than both the bolt and the nut member and that deforms to form a seal with the bolt and the nut member when the system is clamped together.

[0035] Embodiments of the present invention generally relate to fluid processing circuits requiring tube or hose end fittings, where a clamping force is applied to form a leak-tight joint. The clamping force is generated by applying torque to a mechanical fastener that joins two or more parts to form an intimate contact. One or more of the parts in the joint are softer than the others, typically a washer or clamped component, and deform under the clamping load to promote a leak-tight seal. However, even with normal torque application, leakage can occur if the material does not deform sufficiently to seal the fluid passage. This is because the adjacent soft and hard surfaces are flat and smooth, so the seal must primarily rely on the stiffness difference between the soft and hard materials. Embodiments of the present invention create a more effective seal by integrating geometries that promote deformation of the softer material.

[0036] The present invention also includes embodiments that relate to indicating the clamping force in a bolted joint, thereby facilitating control of the clamping force in a bolted joint. Torque is commonly used to achieve a desired clamping load, but due to variations in frictional forces, there is usually a large variation in the actual clamping load. Embodiments of the present invention integrate geometry into the fastener to create a visual clamping load indicator that serves to identify when the desired clamping load has been achieved.

[0037] The present invention also includes embodiments that relate to providing a seal to a clinch fastening system.

[0038] In an embodiment of the present invention, a fastening system is provided, the fastening system including a non-deforming fastener having at least one outer portion, the at least one outer portion of the non-deforming fastener contacting a deformable member to deform the deformable member.

[0039] In an embodiment of the invention, a deformable fastening system includes a deformable member and a non-deformable mating member. The non-deformable mating member is a fastener including a bolt, the bolt having a shaft and a head, the shaft having threads formed thereon, and at least one internal step formed on the underside of the head. The bolt shaft is inserted through a passage in the deformable member and engages with corresponding threads on the nut member, and the bolt head is rotated so that the bolt threads into the nut member during a tightening cycle. The at least one internal step of the bolt engages with the mating surface of the deformable member as the bolt threads into the nut member, clamping the deformable member, thereby increasing the axial load during the tightening cycle and deforming the deformable member.

[0040] In an embodiment of the invention, a deformable fastening system includes a clamped component and a fastener including a bolt, the bolt having a shaft and a head, the shaft having threads formed thereon, and at least one internal step formed on an underside of the head. The underside of the head has at least one internal step formed thereon, defining at least one outer portion of the head. The bolt shaft is inserted through a hole in the clamped component and engages corresponding threads on a nut member, and the bolt head is rotated to drive the bolt into the nut member during a tightening cycle. As the bolt drives into the nut member, the at least one internal step of the bolt engages a mating surface of the clamped component to clamp the clamped component, thereby increasing an axial load and deforming the clamped component during the tightening cycle.

[0041] In an embodiment of the invention, the non-deforming fastener is a bolt having a shaft and a head, the head having a lower surface including at least one step defining at least one outer portion, the at least one step engaging the deformable member to deform the deformable member and continue to deform the deformable member until the outer portion contacts the deformable member at a desired clamping load.

[0042] In an embodiment of the invention, at least one step defining at least one outer portion of the non-deforming fastener engages the mating surface of the deformable member as the bolt enters, clamping the deformable member, thereby significantly increasing torque during the tightening cycle compared to a conventional head with a flat, non-stepped lower surface, indicating that a predetermined clamp load has been achieved. During installation, the deformable member is deformed by increasing axial load until the desired clamp load is reached. When torque and angle feedback installation equipment is used, a sudden increase in torque occurs when the lower surface engages the component to be clamped. This feedback enables the installation equipment to ensure full contact and that the required clamp load has been achieved.

[0043] In an embodiment of the invention, a deformable fastening system includes a clamped component and a fastener including a bolt having a shaft portion extending along a longitudinal axis of the fastener, the shaft portion having a locking portion formed thereon, the shaft portion of the bolt being inserted through a passage in the clamped component and engaging corresponding threads on a nut member, and the head portion of the bolt being rotated such that the bolt threads into the nut member during a tightening cycle.

[0044] The head portion of the fastener includes a surface having at least one engaging portion and one or more protrusions formed on the at least one engaging portion. The one or more protrusions are formed on the at least one engaging portion of the surface of the head portion, typically proximate the shaft portion, in a generally circular and concentric arrangement with the longitudinal axis and the shaft portion. The one or more protrusions formed on the at least one engaging portion of the surface of the head of the bolt engage a mating surface of the clamped component as the bolt is driven into the nut member to clamp the clamped component, thereby increasing the axial load during the tightening cycle and deforming the clamped component.

[0045] In an embodiment of the invention, the fastener includes a bolt having a shaft portion extending along the longitudinal axis of the fastener, with a securing portion formed on the shaft portion. At least one engagement portion is integrally formed on a surface of a head portion of the fastener. The at least one engagement portion includes one or more protrusions formed on the surface of the head portion, typically proximate to the shaft portion, in alignment with the longitudinal axis and the shaft portion. The one or more protrusions include at least one first protrusion extending generally circumferentially around the surface of the head portion relative to the longitudinal axis. The at least one first protrusion is formed in at least one geometric shape as part of the surface of the head portion of the fastener and provides a sealing structure between the fastener and the clamped component.

[0046] In another embodiment, the fastener includes a bolt having a head portion and a shaft portion extending along the longitudinal axis of the fastener, with a securing portion formed on the shaft portion. At least one engaging portion is integrally formed on a surface of the head portion. The at least one engaging portion includes one or more protrusions formed on the surface of the head portion, typically proximate the shaft portion, in alignment with the longitudinal axis and the shaft portion. The one or more protrusions include at least one first protrusion extending generally circumferentially around the surface of the head portion relative to the longitudinal axis. The at least one first protrusion is formed with at least one geometric shape as part of the surface of the fastener head portion and provides a sealing structure between the fastener and the clamped component. A second protrusion extends generally circumferentially around the surface of the head portion relative to the longitudinal axis. The second protrusion is formed as a plurality of separate members cooperatively arranged to extend circumferentially around the surface of the head portion, providing multiple continuous lines of contact between the one or more protrusions and the clamped component.

[0047] One or more embodiments will now be described, by way of example, with reference to the accompanying drawings. [Brief explanation of the drawings]

[0048] [Figure 1A] 1 shows an assembled view (partial cross-section) of a prior art fastening system in which a deformable fastener is attached to the end of a brake hose, in a pre-installed state. [Figure 1B] A prior art fastening system in which a deformable fastening member is attached to the end of a brake hose is shown in an enlarged cross-sectional view of FIG. 1A taken along line A-A of FIG. 1A. [Figure 2A] 1 shows an assembled view (partial cross-section) of a prior art fastening system in an installed state, in which a deformable fastener is attached to the end of a brake hose. [Figure 2B] A prior art fastening system in which a deformable fastening member is attached to the end of a brake hose is shown in an enlarged cross-sectional view of FIG. 2A taken along line B-B of FIG. 2A. [Figure 3] 1 shows a top view of a deformable washer according to a first embodiment of the present invention, the deformable washer having outer portions on both its top and bottom, each outer portion having a rectangular side profile. [Figure 4] 4 shows a side view of the deformable washer shown in FIG. 3. [Figure 5A] 5 shows an assembled view (partial cross-section) of a deformable fastening system according to an embodiment of the present invention, including a deformable member that is a stepped washer as shown in FIGS. 3 and 4 and attached to the end of a brake hose, in a pre-installed state. [Figure 5B] A deformable fastening system according to an embodiment of the present invention, including a deformable member that is a stepped washer as shown in FIGS. 3 and 4 and attached to the end of a brake hose, is shown in an enlarged cross-sectional view of FIG. 5A taken along line C-C of FIG. 5A. [Figure 6A] 5 shows an assembled view (partial cross-section) of a deformable fastening system according to an embodiment of the present invention, including a deformable member that is a stepped washer as shown in FIGS. 3 and 4 and attached to the end of a brake hose, in an installed state. [Figure 6B] A deformable fastening system according to an embodiment of the present invention, including a deformable member that is a stepped washer as shown in Figures 3 and 4, attached to the end of a brake hose, is shown in an enlarged cross-sectional view in Figure 6B taken along line D-D in Figure 6A. [Figure 7] 1 shows a top view of a deformable washer according to a second embodiment of the present invention, the deformable washer having a tapered shape at both its top and bottom. [Figure 8] 8 shows a side view of the deformable washer shown in FIG. 7. [Figure 9A] 7 and 8 show an assembled view (partial cross-section) of a deformable fastening system according to another embodiment of the present invention, including a deformable member that is a tapered washer as shown in FIG. 7 and FIG. 8 and attached to the end of a brake hose, in a pre-installed state. [Figure 9B]A deformable fastening system according to another embodiment of the present invention, including a deformable member that is a tapered washer as shown in Figures 7 and 8, attached to the end of a brake hose, is shown in an enlarged cross-sectional view of Figure 9A taken along line E-E of Figure 9A. [Figure 10A] 7 and 8 show an assembled view (partial cross-section) of a deformable fastening system according to another embodiment of the present invention, including a deformable member that is a tapered washer as shown in FIG. 7 and FIG. 8 and attached to the end of a brake hose, in an installed state. [Figure 10B] A deformable fastening system according to another embodiment of the present invention, including a deformable member that is a tapered washer as shown in Figures 7 and 8, attached to the end of a brake hose, is shown in an enlarged cross-sectional view in Figure 10B taken along line F-F in Figure 10A. [Figure 11] 1 illustrates a top view of a non-deforming fastener of a fastening system defined by a bolt, according to an embodiment of the present invention. [Figure 12] 12 shows a cross-sectional side view of the bolt shown in FIG. 11 taken along line G-G of FIG. 11. [Figure 13] 13 shows a bottom view of the bolt shown in FIGS. 11 and 12. FIG. [Figure 14] 1 illustrates a fastening system according to an embodiment of the present invention in a pre-installed state. [Figure 15] 1 shows a fastening system according to an embodiment of the present invention in an installed state. [Figure 16] 1 illustrates a side view of a deformable fastening system including a non-deforming fastener defined by a bolt in a pre-installed state according to another embodiment of the present invention. [Figure 17] A deformable fastening system including a non-deforming fastener defined by a bolt according to another embodiment of the present invention is shown in cross-sectional view at section H-H in FIG. [Figure 18] A deformable fastening system including a non-deforming fastener defined by a bolt according to another embodiment of the present invention is shown in a bottom view in FIG. [Figure 19]19 after installation, installed to form a deformable fastening system sealed with a deformable member. FIG. [Figure 20] 1 shows a perspective view of a fastening system according to an embodiment of the present invention. [Figure 21] 1 illustrates a bottom view of a fastening system according to an embodiment of the present invention. [Figure 22] 1 illustrates a side view of a fastening system according to an embodiment of the present invention. [Figure 23] 1 illustrates a side cross-sectional view of a portion of a head of a fastener in a fastening system according to an embodiment of the present invention. [Figure 24] 1 illustrates a top view of a fastener of a fastening system positioned proximate a workpiece or component according to an embodiment of the present invention. [Figure 25] 1 illustrates a cross-sectional side view of a fastening system positioned proximate a workpiece or component according to an embodiment of the present invention. [Figure 26] 1 illustrates a cross-sectional side view of a portion of a head of a fastener in a fastening system positioned adjacent to a workpiece or component in a pre-installed state in accordance with an embodiment of the present invention. [Figure 27] 1 illustrates a cross-sectional side view of a fastening system engaging a portion of a workpiece or component in a pre-installed state according to an embodiment of the present invention. [Figure 28] 1 illustrates a cross-sectional side view of a portion of a head of a fastener in a fastening system engaging a portion of a workpiece or component in an installed state according to an embodiment of the present invention. [Figure 29] 10 shows a perspective view of another aspect of a fastening system in an installed state according to an embodiment of the present invention. FIG. DETAILED DESCRIPTION OF THE INVENTION

[0049] The accompanying drawings may present somewhat simplified representations of the various features of the present disclosure disclosed herein, including, for example, specific dimensions, orientations, positions, and shapes, the details of which are determined in part by the particular intended application and environment of use.

[0050] The components of the embodiments of the present disclosure described and illustrated herein can be arranged and designed in a variety of different configurations. Thus, the following detailed description is not intended to limit the scope of the disclosure as claimed, but merely represents possible embodiments of the disclosure. Moreover, although the following description sets forth numerous specific details to provide a thorough understanding of the embodiments disclosed herein, some embodiments can be practiced without some of these details. Moreover, for purposes of clarity, certain technical material understood in the relevant art has not been described in detail to avoid unnecessarily obscuring the present disclosure.

[0051] The drawings are in simplified form and are not to scale. For convenience and clarity only, directional terms such as upper, lower, top, bottom, left, right, up, over, above, below, beneath, rear, and front may be used with respect to the drawings. These and similar directional terms are not to be construed as limiting the scope of the present disclosure. Moreover, the present disclosure as illustrated and described herein may be practiced in the absence of any element not specifically disclosed herein.

[0052] The detailed description is merely exemplary in nature and is not intended to limit application and use. No limitation to any express or implied theory is intended to be imposed herein. The use of ordinal numbers such as first, second, and third does not necessarily imply a ranked order, but rather merely distinguishes between multiple instances of an act or structure.

[0053] The deformable fastening system includes a deformable member and a mating member that forms a seal with the deformable member. Figure 3 provides a top view of a deformable member defined by a stepped washer 30 according to an embodiment of the present invention, and Figure 4 provides a side view of the same washer 30. As shown in Figures 3 and 4, the washer 30 includes at least one outer portion 32, shown as two outer portions 32 on both the top 34 and bottom 36 of the washer 30 (although Figures 3 and 4 show one step 32 on both the top 34 and bottom 36 of the washer, only one outer portion may be provided on only one side of the washer 30. Furthermore, the washer 30 may be provided with multiple outer portions on each of the top 34 and bottom 36, or even a different number of outer portions on each of the top 34 and bottom 36), and a hole 38 is provided in the center 40 of the washer. Thus, washer 30 has a uniform mid-portion with an outer diameter 42 (FIG. 3) defined by the largest measurement, an inner maximum dimension across mid-portion 44 of washer 30, and an inner minimum diameter 46 defined by hole 38 in the center of washer 30.

[0054] In an embodiment of the present invention, the washer has sides, a first side and a second side (top 34 and bottom 38 shown in FIG. 4), the first side and second side being bounded by a first outer axial maximum dimension and a second outer axial maximum dimension, respectively, which dimensions are shown as outer diameters 48, 50 defined by at least one first outer portion and second outer portion (step 32) of the washer 30.

[0055] Preferably, the washer 30 is symmetrical, so that the outer diameters 48, 50 of each of the steps 32 (i.e., the steps 32 on both the top 34 and bottom 36 of the washer 30, respectively) are generally equal.

[0056] The outer portions 32 at the top 34 and bottom 36 of the washer 30 are preferably formed using two opposing dies with step(s) shaped into them. A fixed stroke machine is preferably used to compress the washer material and form the steps using the dies. The steps may be formed using specially shaped tooling (with a stepped shape) during normal washer manufacturing, or may be formed using similar tooling in a secondary operation.

[0057] 5A, 5B, 6A, and 6B show a deformable fastening system 52 used to install the flow bolt 10 on the brake hose 12, which uses the stepped deformable washer 30 shown previously in FIGS. 3 and 4. Specifically, FIGS. 5A and 5B show the state before installation, and FIGS. 6A and 6B show the state after installation. In fact, two stepped washers 30 are used. Thus, in FIGS. 5A, 5B, 6A, and 6B, one washer is identified with reference numeral 30a and the other washer is identified with reference numeral 30b to distinguish them from each other, although both are preferably identical to the washer 30 shown in FIGS. 3 and 4.

[0058] First, a deformable stepped washer 30a (identical to the stepped washer 30 shown in FIGS. 3 and 4) is slid onto the shaft 54 ​​of the flowbolt 10, and then the shaft 54 ​​of the flowbolt 10 is inserted through the bore 14 in the connector 16 on the end of the brake hose 12. At this point, the washer 30a is positioned between the head 22 of the flowbolt 10 and the connector 16. Next, another stepped washer 30b (also preferably identical to the stepped washer 30 shown in FIGS. 3 and 4) is slid onto the shaft 54 ​​of the flowbolt 10, and then a fixing member 26, such as a nut member, is threaded or otherwise engaged with the shaft 54 ​​of the flowbolt 10. At this point, the washer 30b is positioned between the connector 16 and the fixing member 26, and the entire assembly is as shown in FIG. The deformable fastening system 52 is then tightened, such as by rotating the head 22 and / or fastening member 26 of the flowbolt 10, or the fastening member 26 is crimped onto the shaft 54 ​​of the flowbolt 10. In either case, tightening the fastening system 52 compresses or crushes the stepped washers 30a, 30b against the connector 16, thereby forming a seal. During installation, the top 34 and bottom 36 of each washer 30a, 30b may be crushed (see FIG. 6), such that the thickness of each washer after installation is equal to the thickness of the middle portion 44 of each washer (shown in FIG. 4 for illustrative purposes) that was present before installation (see FIGS. 5A and 5B), although this is not required.

[0059] When washers 30a, 30b have at least an outer portion 32 on both the top 34 and bottom 36 (see identical washer 30 shown in Figures 3 and 4) and are substantially pre-crushed before use in a flow bolt installation process, the reduced contact area of ​​the sealing joint results in reduced clamping force compared to the contact area of ​​a conventional, unstepped washer. Treating washer 30 shown in Figures 3 and 4 to provide one or more outer portions on both the top 34 and bottom 36 reduces the force required to install, for example, a flow bolt, while still maintaining the radial strength of the washer. Furthermore, the washer 30 has a first thickness 49 before being attached to the deformable fastening system, which is equal to the sum of the intermediate portion thickness 43a measured longitudinally across the information-carrying intermediate portion and the step thickness 45 measured longitudinally across at least one step (or across each step, if there are multiple steps); once attached to the deformable fastening system, deformation of the washer causes the washer to have a second thickness 43b equal to the intermediate portion thickness 43a (shown in FIG. 6B).

[0060] In contrast, conventional washers are single-thickness and have a larger crush area than is necessary to seal and ensure sufficient radial strength. Crush area is reduced approximately by the amount of thread strength reduced, so washer design is preferably adapted to compensate for the reduced thread strength. If the flow bolt includes one or more external flutes 28 across the threads to provide a fluid flow path, as shown in FIGS. 5 and 6, thread strength may be compromised in that the threads of either the flow bolt 10 or the nut member 26 may be more susceptible to stripping. The use of stepped washers 30a, 30b (see FIGS. 3 and 4, which show identical washers 30) reduces the contact area of ​​the washers compared to conventional washers, thereby requiring less axial force to crush the washers and form a seal against the flow bolt 10 and both the connector assembly 16 and the securing member 26.

[0061] FIG. 7 provides a top view of a deformable member defined by a tapered washer 60 according to another embodiment of the present invention, and FIG. 8 provides a side view of the same washer 60. As shown, the washer 60 includes at least one outer portion having at least one taper 62 and at least one uniform middle portion 72 having an inner maximum dimension 71. In the embodiment of the present invention shown in FIG. 8, there are two tapers 62, which are defined by a first tapered shape and a second tapered shape, respectively. As shown in FIG. 8, there are also two planar portions, a first planar top portion 64 and a second planar bottom portion 66, which define the first and second outer surfaces of the washer, respectively, and a center 70 of the washer with a hole 68 and an inner minimum diameter 63.

[0062] The first planar top 64 and second planar bottom 66 define a first maximum outer dimension 65 and a second maximum outer dimension 67, respectively, which are smaller than a first maximum inner dimension 71 of a uniform intermediate portion 72 of the washer 60. Preferably, the washer 60 is symmetrical, such that each of the tapers 62 (i.e., the tapers 62 on both the top 64 and bottom 66 of the washer) are generally the same in height and slope.

[0063] Furthermore, the washer 60 (shown in FIG. 8 ) has a first thickness 79 before attachment to the deformable fastening system, which is equal to the sum of a mid-portion thickness 73 a measured longitudinally across the conveying mid-portion and a step thickness 75 measured longitudinally across at least one step (or across each step, if multiple steps are present); upon attachment to the deformable fastening system, deformation of the washer causes the washer to have a second thickness 73 b (shown in FIG. 10B ) equal to the mid-portion thickness 73 a. The taper 62 on the washer 60 is preferably formed using two opposing dies specially shaped to form the taper. A fixed stroke machine is preferably used to compress the washer material and form the taper 62 using the dies. The taper 62 may be formed using a specially shaped tool (having the tapered shape) during normal manufacture of the washer, or may be formed using a similar tool in a secondary operation.

[0064] 9A, 9B, 10A, and 10B show a fastening system 70 used to attach the flow bolt 10 to the brake hose 12. The fastening system uses the tapered washer 60 shown in FIGS. 7 and 8 above. Specifically, FIGS. 9A and 9B show the state before installation, and FIGS. 10A and 10B show the state after installation. In practice, two tapered washers 60 are used. Thus, in FIGS. 12 and 13, one washer is identified with reference numeral 60a and the other washer is identified with reference numeral 60b to distinguish them from each other. Thus, in FIGS. 9A, 9B, 10A, and 10B, one washer is identified with reference numeral 60a and the other washer is identified with reference numeral 60b to distinguish them from each other, although both are preferably identical to the washer 60 shown in FIGS. 7 and 8.

[0065] First, a tapered washer 60a (same as the tapered washer 60 shown in FIGS. 7 and 8) is slid onto the shaft 54 ​​of the flow bolt 10, and then the shaft 54 ​​of the flow bolt 10 is inserted through the bore 14 in the connector 16 on the end of the brake hose 12. At this point, the washer 60a is positioned between the head 22 of the flow bolt 10 and the connector 16. Next, another tapered washer 60b (also preferably identical to the tapered washer 60 shown in FIGS. 7 and 8) is slid onto the shaft 54 ​​of the flow bolt 10. Next, a fixing member 26, such as a nut member, is threaded or otherwise engaged with the shaft 54 ​​of the flow bolt 10. At this point, the washer 60b is positioned between the connector 16 and the fixing member 26, and the entire assembly is as shown in FIGS. 9A and 9B. The fastening system 70 is then tightened, such as by rotating the head 22 and / or fastening member 26 of the flow bolt 10, or the fastening member 26 is crimped onto the shaft 54 ​​of the flow bolt 10. In either case, tightening the fastening system 70 compresses or crushes the tapered washers 60a, 60b against the connector 16, thereby forming a seal as shown in FIGS. 10A and 10B. During installation, the top 64 and bottom 66 of the washer 60 may be crushed (see FIGS. 10A and 10B), such that the thickness of the washer 60 after installation is approximately equal to the thickness of the middle portion 72 of the washer 60 (shown in FIG. 8) that was present before installation (see FIGS. 9A and 9B), although this is not required.

[0066] When washers 60a, 60b have at least one taper 62 (see identical washer 60 shown in FIGS. 7 and 8) and are substantially pre-crushed before use in the flow bolt installation process, the contact area of ​​the washer that forms the sealed joint is reduced, resulting in reduced clamping force, compared to the contact area of ​​a conventional, non-tapered washer. By having at least one taper 62 on the top 64 and bottom 66 of washers 60a, 60b, the force required to attach the washer to form a seal with, for example, flow bolt 10 and connector assembly 16 is reduced, while still maintaining the radial strength of washers 60a, 60b. In that the crush area is reduced approximately by the amount of thread strength reduced, the washer design is preferably adapted to compensate for the reduced thread strength. As previously mentioned, if the flow bolt 10 includes one or more external flutes 28 across the threads to provide a fluid flow path (as shown in FIGS. 9A, 9B, 10A, 10B), thread strength may be compromised in that the threads of either the bolt or nut member may be more susceptible to stripping. The use of tapered washers 60a, 60b (see FIGS. 7 and 8, which show identical washers 60) reduces the crush area compared to conventional washers, thereby requiring less axial force to crush the washers and form a seal against the flow bolt 10, as well as against both the connector assembly 16 and the securing member 26.

[0067] The stepped washers and tapered washers shown in Figures 3-4 and 7-8, respectively, can be used to install standard non-flow bolts as well as flow bolts, particularly flow bolts having one or more external flutes extending across the threads. In either case, the use of the non-conventional washers disclosed herein reduces the crush area and, as a result, less clamping force is required for proper installation. Even standard flow bolts that do not have one or more external flutes machined or otherwise formed across the threads benefit from reduced clamping loads due to the smaller cross-sectional area of ​​the bolt.

[0068] During installation, increasing axial load deforms the deformable fastener (i.e., the stepped or tapered washer described above) until the desired clamp load is reached. The outer portion results in a smaller contact area than that of a traditional non-deformable or non-stepped washer. Even though there is less material in contact, the loaded washer material deforms more, better sealing any voids in the joint. This seals the joint with less axial force (torque) than if a standard crush washer were used.

[0069] 11, 12, and 13 provide a top view, a side cross-sectional view, and a bottom view, respectively, of a non-deformable fastener defined by a bolt 100, according to an embodiment of the present invention. As shown, the bolt 100 includes a head 102 (see FIGS. 11 and 12) and a shaft 104 (see FIGS. 12 and 13) having threads 106 formed thereon. Both the head 102 and the shaft 104 may be conventional, except for a lower surface 108 underlying the head 102, which is provided such that the lower surface 108 of the head 102 of the bolt 100 has at least one internal step or engagement portion 110 formed in a portion of the lower surface 108, the at least one internal step 110 defining at least one outer portion of the deformable fastening system.

[0070] In embodiments of the present invention, at least one geometric feature may be formed on the lower surface 108, which may be a "torque-stealing feature," for example, adding texture or ribs to the lower surface 108 that provide high friction to the lower surface 108 when it contacts a mating surface of a deformable member, such as the clamped component 124. It will be appreciated that the clamped component 124 may be formed from a variety of materials, including, but not limited to, polymers, metals, and the like. It is contemplated that the clamped component 124 may have a layer of material applied to it, such as a paint or coating. The layer of material may cooperate with the clamped component to provide additional features, such as a decorative appearance, material protection, or other physical or aesthetic function. The texture may be any geometric feature that transforms the lower surface 108 into a high-friction surface. One such feature may preferably be at least one geometric feature integrally formed on the metal bolt 100, such as texture or ribs added to the lower surface 108, which provides the lower surface 108 with a high friction surface, allowing the required clamping load to be reached more quickly and requiring less torque to be applied to seal the deformable fastening system.

[0071] As shown in FIG. 13 , at least one step or engagement portion 110 is preferably circular and concentric with the shaft 104 (and typically the bolt 100). FIGS. 14 and 15 provide cross-sectional views of a fastening system 120 according to an embodiment of the present invention. The fastening system 120 utilizes the bolt 100 previously shown in FIGS. 11-13 , as well as a nut member 122 and a clamped component 124, such as a workpiece, disposed between the nut member 122 and the underside 108 of the head 102 of the bolt 100. The clamped component 124 is preferably made of a material softer than both the metal bolt 100 and the nut member 122, such as a metal, polymer, or composite. In another embodiment, if the clamped component 124 is not deformable, a deformable washer (not shown) may be utilized.

[0072] In the embodiment shown in Figures 14-15, the bolt 100 is a non-deforming fastener and the clamped component is a deforming member. However, in another embodiment of the present invention, the at least one step or engaging portion 110 can be a softer material than the mating surface and can deform to form a seal against the mating surface. In this embodiment, the at least one step is a deformable member and the mating surface is a mating member. In yet another embodiment, the at least one step 110 formed on the underside of the head 102 of the fastener 100 and the clamped component 124 are each deformable when the at least one step 102 is mated with the clamped component 124.

[0073] Figure 14 shows the fastening system 120 before the bolt 100 is installed, while Figure 15 shows the fastening system 120 after the bolt 100 has been installed. As shown in Figure 14, the shaft 104 of the bolt 100 is initially inserted through a hole or passage 126 in the clamped component 124, and the threads 106 on the shaft 104 engage with corresponding threads 128 on the nut member 122, thereby effectively capturing the clamped component 124 or workpiece between the head 102 of the bolt 100 and the nut member 122.

[0074] In one embodiment of a tightening cycle, the bolt 100 is rotated using the head 102 to fully seat the bolt 100 and nut member 122 with the clamped component 124, causing the bolt 100 to penetrate more fully into the nut member 122 and clamp the clamped component 124. In another embodiment of a tightening cycle, the nut member 122 is rotated along the threads 106 of the shaft 104 of the bolt 100 to move the nut member 122 toward the head 102 of the bolt 100 and capture the clamped component 124 therebetween. By providing at least one internal step or one or more external portions of the engagement portion 110 below the head 102 (i.e., on the underside 108 of the head 102), torque during the tightening cycle is significantly increased, indicating that a predetermined clamp load has been achieved, compared to a conventional head having a flat, unstepped underside.

[0075] During installation, the increasing axial load deforms the clamped material (i.e., the clamped component 124) until the desired clamp load is reached. The area of ​​the outer portion 110 is calculated so that the required clamp load is reached when the lower surface 108 of the bolt 100 (i.e., the surface designated by reference numeral 108 in FIG. 14 ) contacts the clamped component 124. Thus, sufficient clamp load is visually verified when there is no gap between the lower surface (i.e., the surface designated by reference numeral 108 in FIG. 14 ) and the clamped component 124. Furthermore, when torque and angle feedback installation equipment is used, a sudden increase in torque occurs when the lower surface (i.e., the surface designated by reference numeral 108 in FIG. 14 ) engages the clamped component 124. This feedback allows the installation equipment to ensure full contact and that the required clamp load has been achieved.

[0076] While the bolt 100 is shown with an external hex-shaped head 102, the head 102 may be provided with many other different shapes, such as an internal hex-shaped head, or even either an internal or external multi-lobe shape. Additionally, while the term nut member is used with reference to part number 122, the nut member may be any member for attaching the bolt. Thus, the clamped component may be any member that is clamped or captured between a mating member and another component of the deformable fastening system. Finally, the clamped component 124 may be a member that provides clamping in an overall assembly using the bolt 100. In another embodiment of the system, the non-deforming fastener includes a clinch fastener that forms a seal with and clinches against the deformable member.

[0077] 16-19, a deformable fastening system according to another embodiment of the present invention, deformable fastening system 220 (shown in FIG. 19) includes a non-deformable fastener defined by a bolt 200 having a clinching mechanism. FIG. 16 shows the system before installation, FIG. 17 shows a cross-sectional view of section H-H of FIG. 16, FIG. 18 shows a bottom view of FIG. 16, and FIG. 19 shows the system after installation, where the deformable member is a crimping or mating material 222.

[0078] As shown, bolt 200 includes a head 202 (see FIGS. 16 and 19) and a shaft 204 (see FIGS. 16, 18, and 19), similar to bolt 100 of FIGS. 11-15. Both head 202 and shaft 204 may be conventional, except for a lower surface 208 underlying head 200, which is provided with at least one internal step 210 thereon (shown in detail in FIG. 17), with the lower surface 208 and at least one internal step 210 having a similar shape to the corresponding lower surface 108 and at least one internal step 210 associated with bolt 100.

[0079] As shown in FIG. 18, additional features may be added, such as ribs 232, which provide resistance to axial rotation.

[0080] Additionally, bolt 200 includes a clinching feature shown as a retention groove 230 that allows for flow and retention of retained material 222 during the crimping operation (shown in FIG. 19). The retained crimp material 222 is preferably softer than the bolt material. At least one step 210 defining at least one outer portion mates with the crimp material to function as a sealing feature and may include multiple steps to form an additional seal with crimp material 222.

[0081] FIG. 16 shows the fastening system 220 before the bolt 200 is installed, while FIG. 19 shows the fastening system 220 after the bolt 200 is installed within the crimp material 222.

[0082] During installation, the increasing axial load causes the crimping material 222 to deform and some of the crimping material to flow into the retention groove, thereby clinching the crimping material 222 and forming a seal with the crimping material 222 .

[0083] While the embodiments shown in Figures 16-19 are directed to a clinch bolt, additional embodiments may be directed to an equivalent clinching mechanism in a clinch nut.

[0084] With respect to the installation of any of the fastening systems disclosed herein (i.e., those shown in FIGS. 5A, 5B, 6A, 6B, 9A, 9B, 10A, 10B, and 14-15), a programmable drive system may be utilized, preferably capable of implementing a torque-angle tightening strategy. In any event, the bolt and clamped component configurations disclosed herein reduce crush area, thereby requiring substantially less preload to properly install the bolt. Additionally, in some embodiments of the invention shown in FIGS. 16-19, an additional sealing mechanism has been provided.

[0085] 20-28, another embodiment of the fastening system of the present invention is presented. Fastening system 150 includes a fastener or bolt 100 having a head portion 102 that defines a flange portion 101 and an external drive geometry 103. In one embodiment, fastener 100 may be fabricated from one or more of the following materials: titanium, titanium alloy, nickel chromium alloy, stainless steel, mild steel, cast iron, aluminum, aluminum alloy, and the like, but is not limited to these.

[0086] As shown, the external drive geometry 103 of the head 102 includes a plurality of drive faces or walls 105 configured in a hexagonal or "hex" shape. It will be understood that the drive faces or walls of the external drive geometry of the head 102 may be formed in a variety of other geometric shapes or forms, including, for illustrative purposes, an internal hex shape, an internal multi-lobe shape, or an external multi-lobe shape.

[0087] Fastener 100 further defines a shaft portion 104 having a threaded or locking portion 106 formed thereon for mechanically coupling the fastener to a workpiece, clamped component, or the like. Shaft portion 104 extends along and defines a longitudinal axis 107 of fastener 100. As shown, the diameter of shaft portion 104 is smaller than the diameter of flange portion 101 of head portion 102.

[0088] A flange portion 101 of the head portion 102 projects generally radially outward from the longitudinal axis 107 and the shaft portion 104. The flange portion 101 may have a generally circular shape perpendicular to the longitudinal axis 107, or alternatively, a square, hexagonal, or another shape depending on the needs of a particular application. The head portion 102 typically defines a surface 108 incorporating at least one internal step or engagement portion 110.

[0089] 20 and 21, the at least one engagement portion 110 may include one or more protrusions 112, 114. The one or more protrusions 112 may be formed on the surface 108 of the head portion 102, typically proximate the shaft portion 104 of the fastener 100, in a generally circular and concentric arrangement with the longitudinal axis 107 and shaft 104 of the fastener 100. It will be appreciated that other geometric configurations, including, but not limited to, ellipses, may be utilized with the one or more protrusions 112, 114. It will be appreciated that the one or more protrusions 112, 114 of the at least one engagement portion 110 may be formed as one or more single rings extending circumferentially around the surface 108 of the head portion 102.

[0090] In some embodiments, the at least one engaging portion 110 of the head portion 102 of the fastener 100 may include at least one first protrusion 112 extending generally circumferentially around the surface 108 of the head portion 102 relative to the longitudinal axis 107. It is also contemplated that the at least one first protrusion 112 may be formed as a sealing ring. In some embodiments, the at least one first protrusion 112 is integrally formed on the surface 108 of the head portion 102 of the fastener 100. The at least one first protrusion 112 may be provided on the at least one engaging portion 110 of the fastener 100 to provide a sealing structure when the fastener 100 is secured to the clamped component 124.

[0091] In some embodiments, the at least one first protrusion 112 may be formed with a geometric shape as part of the surface 108 of the head portion 102 of the fastener 100, including, but not limited to, multiple arcuate shapes, multiple tapered diameter shapes, etc. The geometric shape of the at least one first protrusion 112 may include multiple cooperating shapes, such as overlapping arcuate surfaces, to engage and deform the workpiece or clamped component 124 at various depths to provide a sealing structure between the fastener 100 and the clamped component 124, whereby the sealing ring 112 provides multiple continuous lines of contact between the sealing ring 112 and the mating surface of the clamped component 124, protecting the area of ​​the clamped component 124 exposed by one or more of the protrusions 112, 114 from corrosion.

[0092] 23, 26, and 28, the at least one first protrusion 112 can be formed with multiple geometrically shaped engagement surfaces 116, 118 to engage the workpiece or clamped component at various depths to provide a sealing structure between the fastener 100 and the clamped component 124. In some embodiments, the at least one first protrusion 112 can include two or more protrusions that are arranged in adjacent cooperating structures to form two or more sealing rings.

[0093] The plurality of engagement surfaces 116, 118 may include at least two engagement surfaces formed with various geometric shapes, including, but not limited to, a generally arcuate shape, a tapered diameter shape, etc. In some embodiments, the engagement surface 116 of the at least one first protrusion 112 may be positioned further from the longitudinal axis 107 than the engagement surface 118. In some embodiments, the engagement surface 116 may be positioned higher or further from the surface 108 of the head portion 102 than the height of the engagement surface 118, thereby creating an offset position of the engagement surfaces 116 and 118 and providing distinct engagement depths and an enhanced sealing mechanism when the at least one first protrusion 112 is coupled to the workpiece or clamped component 124.

[0094] It is also contemplated that in some embodiments, the engagement surface 118 of the at least one first protrusion 112 may be positioned further from the longitudinal axis 107 than the engagement surface 116. In some embodiments, the engagement surface 118 may be positioned higher or further from the surface 108 of the head portion 102 than the height of the engagement surface 116, thereby creating an offset position of the engagement surfaces 116 and 118 when the at least one first protrusion 112 is coupled to the workpiece or clamped component 124, providing a distinct depth of engagement and an enhanced sealing mechanism.

[0095] In some embodiments, the deeper offset of engagement surface 116 relative to engagement surface 118 or the deeper offset of engagement surface 118 relative to engagement surface 116 allows an engagement surface higher or further from surface 108 of head portion 102 to engage with the workpiece or clamped component 124 to provide a first sealing structure. The deeper offset of engagement surface 116 helps protect lower engagement surface 118 from damage during material and part handling prior to and during engagement of fastener 100 with clamped component 124. Additionally, the lower engagement surface, designated engagement surface 118, can be formed lower than engagement surface 116 to provide a second sealing structure. In some embodiments, at least one engagement surface 110 of the fastener 100 may include three or more engagement surfaces or rings, and two or more engagement surfaces 116 may be formed higher or more distal from the surface 108 of the head portion 102 than the height or position of the engagement surface 118 to protect the engagement surface 118 from damage during handling of the part, thereby ensuring that the engagement surface 118 provides a sealing structure for the fastener 100 against the clamped component 124.

[0096] 21 and 23 , one or more protrusions of at least one engagement portion 110 of the head portion 102 of the fastener 100 include a second protrusion 114 that extends generally circumferentially around the surface 108 of the head portion 102 relative to the longitudinal axis 107. It will be appreciated that at least one engagement portion 110 can be formed with the second protrusion 114 that extends generally circumferentially around the surface 108 of the head portion 102 relative to the longitudinal axis 107. The second protrusion 114 can be formed radially inward from the at least one first protrusion 112 relative to the longitudinal axis 107. It will also be appreciated that the second protrusion 114 can be formed radially outward from the at least one first protrusion 112 relative to the longitudinal axis 107. It is also contemplated that the at least one engaging portion 110 of the fastener 100 may include only at least one protrusion 112 on the at least one engaging portion 110 of the surface 108 of the fastener 100 .

[0097] The second protrusion 114 may be formed as part of the surface 108 of the head portion 102 of the fastener 100 in any geometric shape, including, but not limited to, a generally arcuate shape. It will be appreciated that a variety of geometric shapes, such as a tapered diameter shape, may be utilized to form the second protrusion 114 on the surface 108 of the head portion 102.

[0098] It is also contemplated that the second protrusion 114 extending from the surface 108 of the head portion 102 may be formed as a ground ring. The ground ring 114 provides multiple continuous lines of contact between the ground ring 114 and the mating surface of the clamped component 124. In some embodiments, the ground ring 114 is provided on at least one engaging portion 110 of the fastener 100 and engages and penetrates a coating, such as paint, applied to the engaging surface 126 of the clamped component 124.

[0099] The cooperation of the second protrusion, which is the grounding ring 114, and the at least one first protrusion, which is the sealing ring 112, allows the grounding ring 114 to be shielded from any external corrosive elements and maintain integrity, while also intended to capture debris generated during installation of the fastener 100 to the clamped component 124, where the grounding ring 114 penetrates and displaces coatings and materials of the clamped component 124. Furthermore, the use of the second protrusion 114 and the at least one first protrusion 112 on the at least one engaging portion 110 of the head portion 102 of the fastener 100 significantly reduces or reduces the torque requirements to seal the clamped component 124 with the fastener 100 compared to standard fasteners, reduces damage to the clamped component 124 or coatings applied to the clamped component 124 resulting from engagement of the fastener 100 in the fastening system 150 compared to standard fasteners, and may reduce or eliminate the use of chemical sealants or sealing washers in the fastening process.

[0100] It will be appreciated that, similar to the at least one first protrusion 112, the second protrusion 114 may be formed on the surface of the head portion 102 using a variety of geometric shapes. Furthermore, for purposes of the present invention, it is contemplated that the second protrusion 114 may be formed with multiple engagement surfaces, including, but not limited to, one or more ramps or scallops of varying heights, as previously described for the multiple engagement surfaces 116, 118 of the at least one first protrusion 112, where the second protrusion 114 includes multiple engagement surfaces to reduce the torque required to deform and engage the engagement surface 126 of the clamped component 124 and provide a grounding structure for the fastener 100 around the second protrusion 114. It is also contemplated that the at least one second protrusion 114 may be formed as a sealing ring. The second protrusion 114 may include two or more protrusions, arranged in an adjacent cooperating configuration to form two or more sealing rings.

[0101] In some embodiments shown in FIG. 29 , one or more protrusions 112, 114 may be formed as multiple separate members or protrusions cooperatively arranged to extend circumferentially around the surface 108 of the head portion 102, providing multiple continuous lines of contact between the one or more protrusions 112, 114 and the mating surface of the workpiece or clamped component 124, as shown in FIGS. 24 , 27 , and 28 . In some embodiments shown in the figures, the second protrusion 114 is formed as a ground ring having multiple arcuate separate members or protrusions 117 that extend generally circumferentially around the surface 108 of the head portion 102 relative to the longitudinal axis 107. The multiple separate members or protrusions provide multiple continuous lines of contact between the protrusions and the mating surface of the clamped component. It will be understood that the number, location, and geometry of the separate members or protrusions 117 may vary based on the application for the fastener 100.

[0102] The application of multiple, coordinately arranged, separate members to form the ground ring 114 is contemplated, and the use of multiple separate members substantially reduces the surface area, size, and mass of material required to form the ground ring 114 on the fastener 100. It is also contemplated that the use of multiple separate members reduces the overall length of the ground ring 114 that engages the clamped component, thereby requiring a lower torque load to secure the fastener 100 to the clamped component. Additionally, the depth to which the ground ring 114 penetrates the clamped component during the fastening process can be assessed with the multiple separate member configuration shown in FIG.

[0103] 25 and 26 illustrate a fastening system 150, in which the fastener 100 is shown prior to engagement with the workpiece 124. FIG. 25 is a cross-sectional view of the fastening system 150, in which the shaft portion 104 of the fastener 100 extends at least partially through the opening 130 in the workpiece or clamped component 124, and the surface 108 of the head portion 102 is positioned adjacent to the receiving portion 126 of the clamped component 124. One or more protrusions 112, 114 of at least one engaging portion 110 extending from the surface 108 of the head portion 102 are positioned proximate to the receiving surface 126 of the clamped component 124.

[0104] As shown in the figures, the second protrusion 114 is disposed on the surface 108 of the head portion 102 of the fastener 100 proximate the shaft portion 104, while the at least one first protrusion 112 is disposed on the surface 108 of the head portion 102 radially outward from the second protrusion 114. It is also contemplated that the at least one engagement portion 110 of the head portion 102 of the fastener 100 may be formed on the surface 108 of the head portion 102 with only one of the at least one first protrusion 112 or the second protrusion 114.

[0105] 27 and 28, a fastening system 150 is shown in which a fastener 100 engages a workpiece or component 124. As best shown in FIG. 26, one or more protrusions 112, 114 of at least one engaging portion 110 extending from a surface 108 of the head portion 102 engage and deform a receiving portion 126 of the clamped component 124 to create a sealed configuration between the head portion 102 of the fastener 100 and the clamped component 124.

[0106] The cooperation of the second protrusion, which is the grounding ring 114, and the at least one first protrusion, which is the sealing ring 112, allows the grounding ring 114 to be shielded from any external corrosive elements and maintain integrity, while also intended to capture debris generated during installation of the fastener 100 to the clamped component 124, which the grounding ring 114 penetrates into the coating. Additionally, the use of the first protrusion 112 and the at least one second protrusion 114 on the at least one engaging portion 110 of the head portion 102 of the fastener 100 significantly reduces or reduces the torque requirements to seal the clamped component 124 with the fastener 100 compared to standard fasteners, reduces damage to the clamped component 124 or coatings applied to the clamped component 124 resulting from engagement of the fastener 100 in the fastening system 150 compared to standard fasteners, and may reduce or eliminate the use of chemical sealants or sealing washers in the fastening process.

[0107] The detailed description and drawings or figures support and explain the disclosure, the scope of which is defined only by the claims. Although some of the best modes and alternative embodiments for carrying out the disclosure have been described in detail, there are various alternative designs and embodiments for practicing the disclosure as defined by the claims.

Claims

1. a clamped component; a fastener including a bolt; A deformable fastening system comprising: the bolt has a shaft portion and a head portion, the shaft portion extending along a longitudinal axis of the fastener, the shaft portion having a fixing portion formed thereon, and the head portion including at least one engagement portion on a surface thereof; the shaft portion of the bolt is inserted through a passage in the clamped component and engages corresponding threads on a nut member, and the head portion of the bolt is rotated so that the bolt threads into the nut member during a tightening cycle; the at least one engagement portion includes one or more protrusions formed on the surface of the head portion, generally proximate to the shaft portion, in alignment with the longitudinal axis and the shaft portion; the one or more protrusions formed on the at least one engaging portion of the surface of the head of the bolt engage a mating surface of the clamped component as the bolt enters the nut member, thereby increasing an axial load during the tightening cycle and deforming the clamped component. The deformable fastening system.

2. The deformable fastening system of claim 1 , wherein the one or more protrusions include at least one first protrusion extending generally circumferentially around the surface of the head portion relative to the longitudinal axis.

3. 3. The deformable fastening system of claim 2, wherein the at least one first protrusion is formed with at least one geometric shape as part of the surface of the head portion of the fastener to provide a sealing structure between the fastener and the mating surface of the clamped component.

4. 4. The deformable fastening system of claim 3, wherein the at least one geometric shape of the at least one first protrusion is formed with a plurality of arcuate engagement surfaces as part of the surface of the head portion of the fastener to engage the clamped component at various depths and provide a sealing arrangement between the fastener and the mating surface of the clamped component.

5. 5. The deformable fastening system of claim 4, wherein the plurality of arcuate engagement surfaces are formed at offset locations on the at least one first protrusion to provide distinct depths of engagement and to provide a sealing arrangement between the fastener and the mating surface of the clamped component.

6. 2. The deformable fastening system of claim 1, wherein the one or more protrusions of the at least one engagement portion of the head portion of the fastener include a second protrusion extending generally circumferentially around the surface of the head portion relative to the longitudinal axis.

7. 7. The deformable fastening system of claim 6, wherein the second protrusion is formed with at least one geometric shape as part of the surface of the head portion of the fastener to form a ground ring.

8. 8. The deformable fastening system of claim 7, wherein the at least one geometric shape of the second protrusion is formed in an arcuate shape as part of the surface of the head portion of the fastener, forming the ground ring.

9. 7. The deformable fastening system of claim 6, wherein the second protrusions are formed as a plurality of separate members cooperatively arranged to extend circumferentially around the surface of the head portion to provide a plurality of continuous lines of contact between the one or more protrusions and the mating surface of the clamped component.

10. 2. The deformable fastening system of claim 1, wherein the at least one first protrusion is a sealing ring and the second protrusion is a grounding ring positioned radially inward from the at least one first protrusion relative to the longitudinal axis.

11. 2. The deformable fastening system of claim 1, wherein the one or more protrusions of the at least one engaging portion are formed in a generally circular and concentric arrangement as one or more rings extending circumferentially around the surface of the head portion to provide a continuous plurality of contact lines between the one or more protrusions and the mating surface of the clamped component.

12. Bolt and at least one engagement portion; A fastener comprising: the bolt having a head portion and a shaft portion, the shaft portion extending along a longitudinal axis of the fastener, the shaft portion having a fixing portion formed thereon; the at least one engagement portion is formed on a surface of the head portion, the at least one engagement portion including one or more protrusions, the one or more protrusions being formed on the surface of the head portion generally proximate the shaft portion and in alignment with the longitudinal axis and the shaft portion; the one or more protrusions include at least one first protrusion extending generally circumferentially around the surface of the head portion relative to the longitudinal axis; the at least one first protrusion is formed with at least one geometric shape as part of the surface of the head portion of the fastener to provide a sealing structure between the fastener and the clamped component; The fastener.

13. 13. The fastener of claim 12, wherein the at least one geometric shape of the at least one first protrusion is formed with a plurality of arcuate engagement surfaces as part of the surface of the head portion of the fastener to engage the clamped component at various depths and provide a sealing arrangement between the fastener and the clamped component.

14. 14. The fastener of claim 13, wherein the plurality of arcuate engagement surfaces are formed at offset locations on the at least one first protrusion to provide distinct depths of engagement and to provide a sealing arrangement between the fastener and the clamped component.

15. 13. The fastener of claim 12, wherein the one or more protrusions of the at least one engaging portion of the head portion of the fastener include a second protrusion extending generally circumferentially around the surface of the head portion relative to the longitudinal axis.

16. 16. The fastener of claim 15, wherein the second protrusion is formed with at least one geometric shape as part of the surface of the head portion of the fastener to form a ground ring.

17. 17. The fastener of claim 16, wherein the at least one geometric shape of the second protrusion is formed in an arcuate shape as part of the surface of the head portion of the fastener, forming the ground ring.

18. 16. The fastener of claim 15, wherein the second protrusions are formed as a plurality of separate members cooperatively arranged to extend circumferentially around the surface of the head portion to provide a plurality of continuous lines of contact between the one or more protrusions and the clamped component.

19. 13. The fastener of claim 12, wherein the at least one first protrusion is a sealing ring and the second protrusion is a grounding ring positioned radially inward from the at least one first protrusion relative to the longitudinal axis.

20. 13. The fastener of claim 12, wherein the one or more protrusions of the at least one engagement portion are formed in a generally circular and concentric arrangement as one or more rings extending circumferentially around the surface of the head portion to provide a continuous plurality of lines of contact between the one or more protrusions and the clamped component.

21. Bolt and at least one engagement portion; A fastener comprising: the bolt having a head portion and a shaft portion, the shaft portion extending along a longitudinal axis of the fastener, the shaft portion having a fixing portion formed thereon; The at least one engagement portion is formed on a surface of the head portion, the at least one engagement portion including one or more protrusions, the one or more protrusions being formed on the surface of the head portion generally proximate to the shaft portion and in alignment with the longitudinal axis and the shaft portion, the one or more protrusions being: at least one first protrusion extending generally circumferentially around the surface of the head portion relative to the longitudinal axis, the at least one first protrusion being formed with at least one geometric shape as part of the surface of the head portion of the fastener to provide a sealing structure between the fastener and the clamped component, the one or more protrusions further comprising: a second protrusion extending generally circumferentially around the surface of the head portion relative to the longitudinal axis, the second protrusion being formed as a plurality of separate members cooperatively arranged to extend circumferentially around the surface of the head portion to provide a plurality of continuous lines of contact between the one or more protrusions and the clamped component; The fastener.

22. 22. The fastener of claim 21, wherein the at least one geometric shape of the at least one first protrusion is formed with a plurality of arcuate engagement surfaces as part of the surface of the head portion of the fastener to engage the clamped component at various depths and provide a sealing arrangement between the fastener and the clamped component.

23. 23. The fastener of claim 22, wherein the plurality of arcuate engagement surfaces are formed at offset locations on the at least one first protrusion to provide distinct depths of engagement and to provide a sealing arrangement between the fastener and the clamped component.

24. 22. The fastener of claim 21, wherein the at least one first protrusion is a sealing ring and the second protrusion is a grounding ring positioned radially inward or radially outward from the at least one first protrusion relative to the longitudinal axis.

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