Fastening devices, systems, and methods

Abstract

A fastener with improved threading for resisting multi-axial forces and off-axis loading scenarios is provided. The fastener may include a shaft and a plurality of helical threads disposed about the shaft. A method of manufacturing the fastener may include contacting at least one first-stage die to the fastener to form an initial helical threadform disposed about a shaft of the fastener and contacting at least one second-stage die to the fastener to deform the initial helical threadform, thus forming a modified helical threadform.

Description

FASTENING DEVICES, SYSTEMS, AND METHODS Cross-Reference to Related Applications

[0001] This application claims the benefit of U.S. Provisional Patent Application Serial No.63 / 651,820, which is hereby incorporated by reference in its entirety. BACKGROUND Field of the Invention

[0002] The disclosure relates generally to fastening devices, systems, and methods. More specifically, the present disclosure relates to fastening devices with improved thread designs, fastening systems utilizing fastening devices with improved thread designs, and methods of manufacturing fasteners with improved thread designs. SUMMARY

[0003] The various fastening devices, systems, apparatus, and methods of the present disclosure have been developed in response to the present state of the art, and in particular, in response to the problems and needs in the art that have not yet been fully solved by currently available fastening devices, systems, and methods. In some embodiments, the fastening devices, systems, and methods of the present disclosure may provide improved bone fixation and load sharing between a bone / fastener interface under multi-axial and off-loading conditions.

[0004] The details of one or more embodiments of the subject matter described in this specification are set forth in the accompanying drawings and the description below. Other potential features, aspects, and advantages of the subject matter will become apparent from the description, the drawings, and the claims. BRIEF DESCRIPTION OF DRAWINGS

[0005] FIGURE 1 is a perspective view a threaded fastener.

[0006] FIGURE 2A illustrates a front perspective view of a fastener.

[0007] FIGURE 2B illustrates a rear perspective view of the fastener of FIG.2A.

[0008] FIGURE 2C illustrates a side view of the fastener of FIG.2A.

[0009] FIGURE 2D illustrates a cross-sectional side view of the fastener of FIG.2A taken along the line A–A shown in FIG.2C.

[0010] FIGURE 3 is a perspective view of a fastener along a side thereof.

[0011] FIGURES 4–60 illustrate respective thread patterns of a fastener.

[0012] FIGURE 61 illustrates a system for forming a fastener.

[0013] FIGURES 62A–62F, 63A–63D illustrate a system for a multi-step process to create a threaded fastener.

[0014] FIGURES 64A–64F, 65A–65D illustrate a system for a multi-step process to create a threaded fastener.

[0015] FIGURES 66A–66C illustrate a system for a multi-step process to create a threaded fastener.

[0016] FIGURES 67A–67D illustrate a system for a multi-step process to create a threaded fastener.

[0017] FIGURES 68A–68E illustrate a fastener.DESCRIPTION OF PARTICULAR EMBODIMENTS

[0018] This disclosure relates generally to fastening devices, systems, apparatus, and methods.

[0019] In the following description, details are set forth by way of example to facilitate discussion of the disclosed subject matter. It should be apparent to a person of ordinary skill in the field, however, that the disclosed embodiments are exemplary and not exhaustive of all possible embodiments.

[0020] Exemplary embodiments of the present disclosure will be best understood by reference to the drawings, wherein like parts are designated by like numerals throughout. It will be readily understood that the components of the present disclosure, as generally described and illustrated in the drawings, could be arranged, and designed in a wide variety of different configurations. Thus, the following more detailed description of the embodiments of the implants, systems, and methods, as represented in the drawings, is not intended to limit the scope of the present disclosure, but is merely representative of exemplary embodiments of the present disclosure.

[0021] The word “exemplary” is used herein to mean “serving as an example, instance, or illustration.” Any embodiment described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments. While the various aspects of the embodiments are presented in the drawings, the drawings are not necessarily drawn to scale unless specifically indicated.

[0022] The following disclosure presents various fasteners for utilization in bone and other tissues as implantable devices (e.g., orthopedic implants, spine implants, sports medicine implants, dental implants, trauma implants, reconstruction implants, extremity implants, craniomaxillofacial (CMF) implants, veterinary implants, etc.) for the purpose of streamlining the present disclosure. However, it will be understood that the various fasteners and helical threading concepts presented herein can be utilized in any medium beyond bones / tissues and / or for any application beyond surgical procedures.

[0023] Example applications / procedures that may utilize any of the fasteners described or contemplated herein, in any configuration and with any of the features described herein, may include, but are not limited to: trauma procedures, spine procedures (e.g., SI fusion, facet fixation, etc.), reconstruction procedures, sports related procedures, ACL / tenodesis procedures, extremity procedures, dental procedures, CMF procedures, veterinary procedures, fracture fixation plate procedures (e.g., distal femur plates, proximal humerus plates, tibial plates, etc.),supplemental Fixation for IBD procedures, intramedullary canal fixation procedures, nail fixation procedures, limb salvage and transfemoral procedures, amputee connection procedures, total shoulder fixation, reverse glenoid fixation, small bone fixation (e.g., podiatric, hand / wrist, etc.), joint fusions, single-tooth implant fixation, jaw / facial reconstruction, dentures fixation, veterinary trauma, species specific procedures (e.g., equine, canine, rabbit, etc.), TPLO, shear fixation, osteotomies, fusions, procedures involving osteoporotic or compromised bone, etc.

[0024] Moreover, fastener types that may utilize any of the thread designs, morphology, and / or features described herein may include, but are not limited to: cortical fasteners, soft tissue fasteners, long fasteners, cannulated fasteners, plate fasteners, locking / non-locking fasteners, dynamic hip fasteners, acetabular cup fasteners, Schanz pins, half pins, pedicle fasteners, cervical fasteners, threaded stems, threaded intramedullary canal stems, joint stems, revision fasteners, compression fasteners (e.g., headless / headed compression fasteners, hip compression fasteners, etc.), ACL fasteners, tenodesis fasteners, bone-tendon-bone graft fasteners, suture anchors, dental fasteners, mandibular tenting fasteners, veterinary fasteners, etc.

[0025] Particular embodiments are best understood by reference to FIGURES 1–68 wherein like numbers are used to indicate like and corresponding parts.

[0026] Referring to FIGURE 1, a threaded fastener 1 includes a threaded portion 2 extending from a first end 3 to a second end 4. The second end 4 may alternatively be referred to as the lead end of the fastener based upon the driving direction of the fastener. In some embodiments, the threaded fastener 1 is a screw having a head 5. The threaded portion 2 is defined by a helical thread extending around an elongated shank 6 that extends from the head 5 to the second end 4. The thread can be defined by at least a crest portion, a leading flank, a root portion, and a trailing flank. The configuration of the thread may be defined by reference to a longitudinal axis and / or a normal axis of the threaded fastener. The longitudinal axis extends through the fastener from the first end to the second end, whereas the normal axis extends perpendicular to the longitudinal axis.

[0027] FIGS.2A–D illustrate an example of the threaded fastener 1 of FIGURE 1, and in particular, illustrate various views of a fastener 100, implantable bone anchor, or bone screw, according to one embodiment of the present disclosure. Specifically, FIG.2A is a front perspective view of the fastener 100, FIG.2B is a rear perspective view ofthe fastener 100, FIG.2C is a side view of the fastener 100, and FIG.2D is a cross-sectional side view of the fastener 100 taken along the line A–A in FIG.2C.

[0028] In general, the fastener 100 may include a shaft 105 having a proximal end 101, a distal end 102, and a longitudinal axis 103. The fastener 100 may also include a head 104 located at the proximal end 101 of the shaft 105, a torque connection interface 106 formed in / on the head 104 (in either a male / female configuration), and a self- tapping feature 107 formed in the distal end 102 of the shaft 105.

[0029] In some embodiments, the fastener 100 may include a first helical thread 110 disposed about the shaft 105, and a second helical thread 120 disposed about the shaft 105 adjacent the first helical thread 110.

[0030] In some embodiments, the fastener 100 may include a “dual start” or “dual lead” thread configuration comprising the first helical thread 110 and the second helical thread 120.

[0031] In some embodiments, a depth of the first helical thread 110 and / or the second helical thread 120 with respect to the shaft 105 may define a major diameter vs. a minor diameter of the shaft 105 alone.

[0032] In some embodiments, a major diameter and / or a minor diameter of the fastener 100 may be constant or substantially constant along the entire length of the fastener, or along a majority of the length of the fastener. In these embodiments, a constant minor diameter may help avoid blowout of narrow / delicate bones (e.g., a pedicle) when inserting a fastener into a bone. In some embodiments, a pilot hole may first be drilled into a narrow / delicate bone and then a fastener having a similar minor diameter in comparison to the diameter of the pilot hole may be chosen to avoid blowout when inserting the fastener into the bone.

[0033] In some embodiments, a depth of the first helical thread 110 and / or the second helical thread 120 with respect to the shaft 105 may vary along a length of the shaft 105 to define one or more major diameters of the fastener 100 and / or one or more regions along the fastener 100 may comprise a one or more continuously variable major diameters.

[0034] In some embodiments, a thickness of the shaft 105 may vary along a length of the shaft 105 to define one or more minor diameters of the fastener 100, and / or one or more regions along the fastener 100 may comprise one or more continuously variable minor diameters. In some embodiments, a thickness / height / width / length / pitch / shape of the first helical thread 110 and / or the second helical thread 120 (or any additional helical thread)may vary along a length of the shaft 105. For example, a thickness / height / width / length / pitch / shape of the first helical thread 110 and / or the second helical thread 120 may be greater towards the tip of the fastener and thinner towards the head of the fastener (or vice versa) in either a discrete or continuously variable fashion, etc.

[0035] In some embodiments, the major and / or minor diameters may increase toward a proximal end or head of a fastener in order to increase bone compaction as the fastener is terminally inserted into the bone / tissue.

[0036] In some embodiments, a pitch of the first helical thread 110 and / or the second helical thread 120 may vary along a length of the fastener 100.

[0037] In some embodiments, the fastener 100 may include a plurality of helical threads disposed about the shaft 105. However, it will also be understood that any of the fasteners disclosed or contemplated herein may include a single helical thread disposed about the shaft of the fastener. Moreover, the fastener 100 may comprise a nested plurality of helical threads having different lengths (not shown). As one non-limiting example, the fastener 100 may include a first helical thread 110 that is longer than a second helical thread 120, such that the fastener 100 comprises dual threading along a first portion of the shaft 105 and single threading along a second portion of the shaft 105.

[0038] In some embodiments, the plurality of helical threads may include three helical threads (not shown) comprising a “triple start” or “triple lead” thread configuration (not shown).

[0039] In some embodiments, the plurality of helical threads may include four helical threads (not shown) comprising a “quadruple start” or “quadruple lead” thread configuration (not shown).

[0040] In some embodiments, the plurality of helical threads may include more than four helical threads (not shown).

[0041] In some embodiments, the fastener 100 may include first threading with any of the shapes disclosed herein oriented toward one of the proximal end and the distal end of the fastener 100 with the first threading located proximate the distal end of the fastener 100, as well as second threading with any of the shapes disclosed herein oriented toward the other one of the proximal end and the distal end of the fastener 100 with the second threading located proximate the head of the fastener 100 (not shown).

[0042] In some embodiments, the fastener 100 may include multiple threading (e.g., dual helical threading, etc.) with any of the shapes disclosed herein located proximate one of theproximal end and the distal end of the fastener 100, as well as single threading with any of the shapes disclosed herein with the second threading located proximate the other of the proximal end and the distal end of the fastener 100 (not shown).

[0043] In some embodiments, the first helical thread 110 may include a plurality of first concave undercut surfaces 131 and a plurality of first convex undercut surfaces 141.

[0044] In some embodiments, the second helical thread 120 may include a plurality of second concave undercut surfaces 132 and a plurality of second convex undercut surfaces 142.

[0045] In some embodiments, when the fastener 100 is viewed in section along a plane that intersects the longitudinal axis 103 of the shaft 105 (as shown in FIG.2D), the plurality of first concave undercut surfaces 131 and the plurality of second convex undercut surfaces 142 may be oriented toward (i.e., point toward) the proximal end 101 of the shaft 105.

[0046] In some embodiments, the plurality of first convex undercut surfaces 141 and the plurality of second concave undercut surfaces 132 may be oriented toward (i.e., point toward) the distal end 102 of the shaft 105.

[0047] In some embodiments, at least one of the plurality of first concave undercut surfaces 131, the plurality of first convex undercut surfaces 141, the plurality of second concave undercut surfaces 132, and the plurality of second convex undercut surfaces 142 may comprise at least one substantially flat surface.

[0048] In some embodiments, when the fastener 100 is viewed in section along a plane intersecting the longitudinal axis 103 of the shaft 105, the first helical thread 110 may comprise a plurality of first bent shapes (comprising at least one surface that is angled relative to the longitudinal axis 103 of the shaft 105 and / or at least one undercut surface) with a plurality of first intermediate portions 151 that are oriented toward (i.e., point toward) the distal end 102 of the shaft 105. This may be referred to as “standard” threading, having a “standard” orientation.

[0049] In some embodiments, when the fastener 100 is viewed in section along a plane intersecting the longitudinal axis 103 of the shaft 105, the second helical thread 120 may comprise a plurality of second bent shapes (comprising at least one surface that is angled relative to the longitudinal axis 103 of the shaft 105 and / or at least one undercut surface) with a plurality of second intermediate portions 152 that are oriented toward (i.e., point toward) the proximal end 101 of the shaft 105. This may be referred to as “inverted” threading, having an “inverted” orientation.

[0050] In some embodiments, one or more helical threads may morph / transition between a standard orientation and an inverted orientation along a shaft of a fastener.

[0051] In some embodiments, at least one of the plurality of first concave undercut surfaces 131, the plurality of first convex undercut surfaces 141, the plurality of second concave undercut surfaces 132, and the plurality of second convex undercut surfaces 142 may comprise at least one curved surface.

[0052] As shown in FIG.2D, the proximally-oriented and distally-oriented surfaces of the first helical thread 110 (i.e., the first concave undercut surfaces 131 and the first convex undercut surfaces 141 in the fastener 100 of FIG.2D) may not have mirror symmetry relative to each other about any plane perpendicular to the longitudinal axis 103 of the fastener 100. Rather, the first concave undercut surfaces 131 and the first convex undercut surfaces 141 may be generally parallel to each other. The same may be true for the second helical thread 120, in which the second concave undercut surfaces 132 and the second convex undercut surfaces 142 do not have mirror symmetry relative to each other, but may be generally parallel to each other.

[0053] Conversely, as also shown in FIG.2D, the proximally-oriented surfaces of the first helical thread 110 may have mirror symmetry relative to the distally-oriented surfaces of the second helical thread 120. Specifically, the first concave undercut surfaces 131 may have mirror symmetry relative to the second convex undercut surfaces 142 about a plane 170 that bisects the space between them, and lies perpendicular to the longitudinal axis 103.

[0054] Similarly, the distally-oriented surfaces of the first helical thread 110 may have mirror symmetry relative to the proximally-oriented surfaces of the second helical thread 120. Specifically, the second concave undercut surfaces 132 may have mirror symmetry relative to the first convex undercut surfaces 141 about a plane 172 that bisects the space between them, and lies perpendicular to the longitudinal axis 103.

[0055] This mirror symmetry may be present along most of the length of the first helical thread 110 and the second helical thread 120, with symmetry across different planes arranged between adjacent turns of the first helical thread 110 and the second helical thread 120 along the length of the longitudinal axis 103. Such mirror symmetry may help more effectively capture bone between the first helical thread 110 and the second helical thread 120, and may also facilitate manufacture of the fastener 100, as will be described in more detail below.

[0056] In some embodiments, when the fastener 100 is viewed in section along a plane intersecting the longitudinal axis 103 of the shaft 105, the first helical thread 110 may includeat least one partial crescent shape that is oriented toward (i.e., points toward) the distal end 102 of the shaft 105 and / or the proximal end 101 of the shaft 105. FIG.10 illustrates a partial cross-sectional view of a fastener 700 comprising crescent shapes, as one non-limiting example of such an embodiment.

[0057] In some embodiments (not shown), when the fastener 100 is viewed in section along a plane intersecting the longitudinal axis 103 of the shaft 105, the first helical thread 110 may include at least one partial crescent shape that is oriented toward (i.e., points toward) the distal end 102 of the shaft 105, and the second helical thread 120 may include at least one partial crescent shape that is oriented toward (i.e., points toward) the proximal end 101 of the shaft 105.

[0058] In some embodiments (not shown), the first helical thread 110 may include a first plurality of partial crescent shapes that are oriented toward (i.e., point toward) the distal end 102 of the shaft 105, and the second helical thread 120 may include a second plurality of partial crescent shapes that are oriented toward (i.e., point toward) the proximal end 101 of the shaft 105.

[0059] In some embodiments (not shown), the first plurality of partial crescent shapes and the second plurality of partial crescent shapes may be arranged in alternating succession along the shaft 105 of the fastener 100.

[0060] In some embodiments, a fastener may have only standard threads or only inverted threads. The type of threads that are desired may depend on the type and / or magnitude of loads to be applied to the fastener. For example, a screw loaded axially away from the bone in which it is implanted may advantageously have a standard thread, while a screw loaded axially toward the bone in which it is implanted may advantageously have an inverted thread. A screw that may experience multi-axial loading and / or off-loading conditions may advantageously include at least one standard thread and at least one inverted thread in order to increase bone fixation and load sharing between a bone / fastener interface during multi-axial and off-loading conditions to reduce high bone strain and distribute multi-axial forces applied to the bone in a load-sharing, rather than load-bearing, configuration. Shear loads and / or bending moments may also be optimally resisted with any chosen combination of threading, threading morphology, and / or threading variations contemplated herein to optimally resist shear loads, bending moments, multi-axial loading, off-loading conditions, etc.

[0061] In some embodiments, fasteners with standard threads may be used in conjunction with fasteners with inverted threads in order to accommodate different loading patterns.

[0062] In some embodiments, a single fastener may have both standard and inverted threads, like the fastener 100. Such a combination of threads may help the fastener 100 remain in place with unknown and / or varying loading patterns.

[0063] In some embodiments, the geometry of the threading of a fastener (with standard and / or inverted threads) may be varied to suit the fastener for a particular loading scheme. For example, the number of threads, the number of thread starts, the pitch of the threading, the lead(s) of the threading, the shape(s) of the threading, any dimension(s) associated with the threading (e.g., any length(s) / width(s) / height(s) associated with the threading), the major diameter(s), the minor diameter(s), any angulation / angles associated with any surfaces of the threading, the “handedness” of the threading (e.g., right-handed vs. left-handed), etc., may be varied accordingly to suit any specific medium of installation, loading pattern, application, procedure, etc., that may be involved.

[0064] In some embodiments, the material(s) of any portion of a fastener described herein may include, but are not limited to metals (e.g., titanium, cobalt, stainless steel, etc.), metal alloys, plastics, polymers, PEEK, UHMWPE, composites, additive particles, textured surfaces, biologics, biomaterials, bone, etc.

[0065] In some embodiments, any of the fasteners described herein may include additional features such as: self-tapping features, locking features (e.g., locking threading formed on a portion of the fastener, such as threading located on or near a head of the fastener), cannulation, any style of fastener head (or no fastener head at all), any style of torque connection interface (or no torque connection interface at all), etc.

[0066] In some embodiments, a tap (not shown) may be utilized to pre-form threading herein in a bone according to any threading shape that is disclosed herein. In this manner, taps with any suitable shape may be utilized in conjunction with any fastener described or contemplated herein to match or substantially match the threading geometry of a given fastener.

[0067] In some embodiments, a minor diameter of the fastener may be selected to match, or substantially match, a diameter of a pilot hole that is formed in a bone to avoid bone blowout when the fastener is inserted into the pilot hole.

[0068] Additionally or alternatively, the type of threads and / or thread geometry may be varied based on the type of bone in which the fastener is to be anchored. For example, fasteners anchored in osteoporotic bone may fare better with standard or inverted threads, or when the pitch, major diameter, and / or minor diameter are increased or decreased, or when the angulation of thread surfaces is adjusted, etc.

[0069] In some embodiments, a surgical kit may include multiple fasteners with any of the different thread options described or contemplated herein. The surgeon may select the appropriate fastener(s) from the kit based on the particular loads to be applied and / or the quality of bone in which the fastener(s) are to be anchored.

[0070] Continuing with FIG.2D, in some embodiments the first helical thread 110 may include a plurality of first undercut surfaces 111, a plurality of second undercut surfaces 112, a plurality of third undercut surfaces 113, and a plurality of fourth open surfaces 114.

[0071] In some embodiments, the second helical thread 120 may include a plurality of fifth undercut surfaces 125, a plurality of sixth undercut surfaces 126, a plurality of seventh undercut surfaces 127, and a plurality of eighth open surfaces 128.

[0072] In some embodiments one or more of the plurality of first undercut surfaces 111, the plurality of second undercut surfaces 112, the plurality of third undercut surfaces 113, the plurality of fourth open surfaces 114, the plurality of fifth undercut surfaces 125, the plurality of sixth undercut surfaces 126, the plurality of seventh undercut surfaces 127, and the plurality of eighth open surfaces 128 may comprise at least one flat or substantially flat surface.

[0073] In some embodiments, the plurality of first undercut surfaces 111, the plurality of third undercut surfaces 113, the plurality of sixth undercut surfaces 126, and the plurality of eighth open surfaces 128 may be angled towards the distal end 102 of the shaft 105.

[0074] In some embodiments, the plurality of second undercut surfaces 112, the plurality of fourth open surfaces 114, the plurality of fifth undercut surfaces 125, and the plurality of seventh undercut surfaces 127 may be angled towards the proximal end 101 of the shaft 105.

[0075] In some embodiments, when the fastener 100 is viewed in section along a plane that intersects the longitudinal axis 103 of the shaft 105 (as shown in FIG.2D), the first helical thread 110 may include at least one chevron shape that is oriented toward (i.e., points toward) the distal end 102 of the shaft 105. Likewise, the second helical thread 120 may also include at least one chevron shape that is oriented toward (i.e., points toward) the proximal end 101 of the shaft 105.

[0076] In some embodiments, when the fastener 100 is viewed in section along a plane that intersects the longitudinal axis 103 of the shaft 105 (as shown in FIG.2D), the first helical thread 110 may include a first plurality of chevron shapes that are oriented toward (i.e., point toward) the distal end 102 of the shaft 105. Likewise, the second helical thread 120 may include a second plurality of chevron shapes that are oriented toward (i.e., point toward) the proximal end 101 of the shaft 105.

[0077] In some embodiments, the first plurality of chevron shapes and the second plurality of chevron shapes may be arranged in alternating succession along the shaft 105 of the fastener 100, (e.g., see FIG.2D).

[0078] In some embodiments, a plurality of first interlocking spaces 161 and a plurality of second interlocking spaces 162 may be formed between the first helical thread 110 and the second helical thread 120 along the shaft 105 of the fastener 100.

[0079] In some embodiments, the plurality of first interlocking spaces 161 may be formed intermediate the first concave undercut surfaces 131 and the second concave undercut surfaces 132.

[0080] In some embodiments, the plurality of second interlocking spaces 162 may be formed intermediate the first convex undercut surfaces 141 and the second convex undercut surfaces 142.

[0081] In some embodiments, the plurality of first interlocking spaces 161 may be larger in size than the plurality of second interlocking spaces.

[0082] In some embodiments, the plurality of first interlocking spaces 161 and the plurality of second interlocking spaces 162 may be shaped and / or configured to interlock with bone / other tissues received therein to increase fixation of the fastener 100 within the bone / other tissues and provide additional resistance against multi-axial forces that may be applied to the fastener 100 and / or the bone / other tissues.

[0083] In some embodiments, the plurality of second undercut surfaces 112 and the plurality of sixth undercut surfaces 126 may be angled toward each other to trap bone / other tissues within the plurality of first interlocking spaces 161 in order to increase fixation and resistance against multi-axial forces.

[0084] In some embodiments, the plurality of third undercut surfaces 113 and the plurality of seventh undercut surfaces 127 may be angled toward each other to trap bone / other tissues within the plurality of second interlocking spaces 162 in order to increase fixation and resistance against multi-axial forces.

[0085] In some embodiments, the plurality of first undercut surfaces 111 and the plurality of fifth undercut surfaces 125 may each form an angle α with respect to the longitudinal axis 103 of the shaft 105, as shown in FIG.2D.

[0086] In some embodiments, the angle α may be greater than 90 degrees.

[0087] In some embodiments, the plurality of second undercut surfaces 112 and the plurality of sixth undercut surfaces 126 may each form an angle β with respect to the longitudinal axis 103 of the shaft 105.

[0088] In some embodiments, the angle β may be less than 90 degrees.

[0089] In some embodiments, the plurality of third undercut surfaces 113 and the plurality of seventh undercut surfaces 127 may each form an angle θ with respect to the longitudinal axis 103 of the shaft 105.

[0090] In some embodiments, the angle θ may be approximately 90 degrees.

[0091] In some embodiments, the angle θ may be greater than 90 degrees.

[0092] Referring FIGURE 3, an example of the threaded fastener 1 of FIGURE 1 is shown, and in particular, a fastener 300. The fastener 300 has an elongated shaft 313, substantially cylindrical along its length with a linear long axis 301 at its center. The screw may have a head 306 provided with a drive face on its top surface. The face can be contoured to accommodate a drive socket, screw driver tip, “torx” fitting, allen wrench, etc. to advance the screw.

[0093] A plurality of thread flights is contemplated, and the drawings illustrate a two flight embodiment. A first flight having a first thread 312 displays a greater crest diameter than a second flight having a second thread 324. In some examples, these two flights are spaced from each other by 180 degrees and enjoy the same pitch. As shown, thread 312 enjoys a greater crest diameter than thread 324.

[0094] In short, the present disclosure discusses fasteners, that in some examples, physically trap the adjacent substrate whether that be bone, metal, polymer, wood, drywall, ceramic, concrete, dirt, ice, stone, etc. The disclosure discusses using two or more leads to create interlocking patterns on screws, fasteners, nuts, bolts, inserts, threaded clips, dual-ended threaded studs or rods, taps, and in substrates (female threadform) to receive a mating component. The fastener geometries disclosed are generally cylindrical in length but could include either a tapered minor diameter, major diameter, or both. The geometries could be generated for use with a tap, could be designed to be self-tapping, or could be on a tap to prepare a substrate. The geometries disclosed are agnostic to material but all trap the adjacent material between threads based on undercut surfaces and geometry. The thread forms could be present on threaded fasteners / screws with or without heads, could be dual or multiple lead, could be on a bolt and / or a nut, an insert nut, a combination of a fastener or nut with these thread forms and a standard buttress thread form, a thread clip, threaded stud, thread screw or post with an overmold, or other embodiments. The thread forms could be present on a drill or tapinstrument, or combination thereof. Any of these variations could have flat tips, pointed tips, self-tapping, could be cannulated or solid, partially, or fully thread, cylindrical or tapered, could have a fixed diameter, a variable diameter, or a consistent or varying pitch. Geometries with undercuts and surfaces that trap the adjacent substrate have demonstrated increased stability in multi-axial loading and resist loads both in tension and compression. Rather than relying on direct compression and radial loading of the substrate material, these designs interlock with the substrate as they are turned in, preserving the volume and integrity of the surrounding substrate for loading and load sharing. The dual lead designs disclosed within this document offer the opportunity to manufacturing these interlocking and undercut designs by traditional machining and turning, or by milling with form tools as the space created between two adjacent threads can alternate shapes and lend itself to form tooling.

[0095] FIGURES 4–60 illustrate varying thread patterns that can be implemented by the fasteners of FIGURES 1–3 (e.g., fastener 1, fastener 100, fastener 300). For example, the thread patterns of FIGURES 4–60 that include single angled threads can be implemented by FIGURE 1 or any appropriate combination / arrangement of threads of FIGURES 1–3; the thread patterns of FIGURES 4–60 that include multi-angled threads can be implemented by FIGURE 2 or any appropriate combination / arrangement of threads of FIGURES 1–3; and the thread pattern of FIGURES 4–60 that include multi-threads can be implemented by FIGURE 3 or any appropriate combination / arrangement of threads of FIGURES 1–3.

[0096] FIGURE 4 illustrates an example thread pattern 400 of a fastener. The thread pattern 400 can include, in general, alternating threads 402a, 402b with inverted triangle and frustum. Specifically, the threads 402a, 402b can extend from a shaft. The threads 402a, 402b extend along at least a portion of the shaft of the fastener. The thread 402a can include an inverted triangle geometric shape; and the thread 402b can include a frustum geometric shape. The thread 402a can extend to a first major diameter, and the thread 402b can extend to a second major diameter; with the first major diameter of the thread 402a being greater than the second major diameter of the thread 402b. In some examples, the threads 402a, 402b can extend to the same major diameter.

[0097] FIGURE 5 illustrates an example thread pattern 500 of a fastener. The thread pattern 500 can include, in general, a thread 502 including “V” undercuts and a “U” shaped channel. Specifically, the thread 502 can extend from a shaft. The thread 502 extends along at least a portion of the shaft of the fastener. The thread 502 can include an undercut surface 504 (similar to the undercut surface 131 and / or the a convex undercut surfaces 141 both of FIGURES 2A–2D). The undercut surface 504 can have any geometric shape with respect to the shaft, and / or any angle with respect to the shaft. In the illustrated example, the undercut surface 504 forms a “V” shape / angle with respect to the shaft of the fastener. The thread 502 can further include a channel 506. The channel 506 can have any geometric shape. In the illustrated example, the channel 506 forms a “U” shape.

[0098] FIGURE 6 illustrates an example thread pattern 600 of a fastener. The thread pattern 600 can include, in general, alternating threads 602a, 602b of hooks and posts. Specifically, the threads 602a, 602b can extend from a shaft. The threads 602a, 602b extend along at least a portion of the shaft of the fastener. The thread 602a can include a hook geometric shape. The thread 602a can include any hooking geometric shape, including a substantially 90 degree hook (from a body of the thread 602a) and a curved hooked (from a body of the thread 602a). The thread 602b can include a post (or column) geometric shape. The thread 602a can extend to a first major diameter, and the thread 602b can extend to a second major diameter; with the first major diameter of the thread 602a being greater than the second major diameter of the thread 602b. In some examples, the first major diameter is substantially the same as the second major diameter.

[0099] FIGURE 7 illustrates an example thread pattern 700 of a fastener. The thread pattern 700 can include, in general, alternating threads 702a, 702b of hooks and posts. Specifically, the threads 702a, 702b can extend from a shaft. The threads 702a, 702b extend along at least a portion of the shaft of the fastener. The threads 702a, 702b can include alternating square hooks. In some examples, the threads 702a, 702b can extend to substantially the same major diameter. In some examples, the threads 702a, 702b can extend to differing major diameters.

[0100] FIGURE 8 illustrates an example thread pattern 800 of a fastener. The thread pattern 800 can include, in general, alternating threads 802a, 802b of hooks and diamonds. Specifically, the threads 802a, 802b can extend from a shaft. The threads 802a, 802b extend along at least a portion of the shaft of the fastener. The thread 802a can include a diamond geometric shape. The thread 802b can include hook geometric shape. The thread 802b can include any hooking geometric shape, including a substantially 90 degree hook (from a body of the thread 802a) and a curved hooked (from a body of the thread 802a). In some examples, the direction of each of the threads 802b – e.g., the direction of the hook of the thread 802b – is substantially the same (e.g., facing the same direction). In some examples, the threads 802a,802b can extend to substantially the same major diameter. In some examples, the threads 802a, 802b can extend to differing major diameters.

[0101] FIGURE 9 illustrates an example thread pattern 900 of a fastener. The thread pattern 900 can include, in general, alternating threads 902a, 902b of hooks. Specifically, the threads 902a, 902b can extend from a shaft. The threads 902a, 902b extend along at least a portion of the shaft of the fastener. The thread 902a can include a hook geometric shape – similar to the first helical pattern 110 and the second helical pattern 120. The thread 902b can include a hook geometric shape – similar to the first helical pattern 110 and the second helical pattern 120. The thread 902a can extend to a first major diameter, and the thread 902b can extend to a second major diameter; with the first major diameter of the thread 902a being greater than the second major diameter of the thread 902b. In some examples, the first major diameter is substantially the same as the second major diameter.

[0102] FIGURE 10 illustrates an example thread pattern 1000 of a fastener. The thread pattern 1000 can include, in general, alternating threads 1002a / 1002c and 1002b of hooks and diamonds. Specifically, the threads 1002a, 1002b, 1002c can extend from a shaft. The threads 1002a, 1002b, 1002c extend along at least a portion of the shaft of the fastener. The threads 1002a, 1002c can include a hook geometric shape – similar to the first helical pattern 110 and the second helical pattern 120. In some examples, the threads 1002a, 1002c can include hook geometric shape. The thread 1002a, 1002c can include any hooking geometric shape, including a substantially 90 degree hook (from a body of the thread 1002a, 1002c) and a curved hooked (from a body of the thread 1002a, 1002c). In some examples, the direction of each of the threads 1002a – e.g., the direction of the hook of the thread 1002a – is substantially the same (e.g., facing the same direction). In some examples, the direction of each of the threads 1002c – e.g., the direction of the hook of the thread 1002c – is substantially the same (e.g., facing the same direction). In some examples, the threads 1002a face in the opposite direction as that of the threads 1002c. The thread 1002b can include a diamond geometric shape. The thread 1002b can be positioned between pairs of threads 1002a / 1002c. The threads 1002a / 1002c can extend to a first major diameter, and the thread 1002b can extend to a second major diameter; with the first major diameter of the threads 1002a / 1002c being greater than the second major diameter of the thread 1002b. In some examples, the first major diameter is substantially the same as the second major diameter.

[0103] FIGURE 11 illustrates an example thread pattern 1100 of a fastener. The thread pattern 1100 can include, in general, alternating threads 1102a, 1102b of hooks. Specifically,the threads 1102a, 1102b can extend from a shaft. The threads 1102a, 1102b extend along at least a portion of the shaft of the fastener. The thread 1102a can include a first hook geometric shape. The thread 1102a can include any hooking geometric shape. The thread 1102b can include a second hook geometric shape, differing from the first hook geometric shape. The thread 1102b can include any hooking geometric shape. In some examples, the direction of each of the threads 1102a – e.g., the direction of the hook of the thread 1102a – is substantially the same (e.g., facing the same direction). In some examples, the direction of each of the threads 1102b – e.g., the direction of the hook of the thread 1102b – is substantially the same (e.g., facing the same direction). In some examples, the threads 1102a face in the same direction as that of the threads 1102b. In some examples, the threads 1102a face in the opposite direction as that of the threads 1102b. In some examples, the threads 1102a, 1102b can extend to substantially the same major diameter. In some examples, the threads 1102a, 1102b can extend to differing major diameters.

[0104] FIGURE 12 illustrates an example thread pattern 1200 of a fastener. The thread pattern 1200 can include, in general, alternating threads 1202a, 1202b of crescents. Specifically, the threads 1202a, 1202b can extend from a shaft. The threads 1202a, 1202b extend along at least a portion of the shaft of the fastener. The thread 1202a can include a first crescent geometric shape. The thread 1202a can include any crescent geometric shape. The thread 1202b can include a second crescent geometric shape. The thread 1202b can include any crescent geometric shape. In some examples, the crescent geometric shape of the threads 1202a, 1202b are substantially the same. In some examples, the crescent geometric shape of the threads 1202a, 1202b are differing. In some examples, the direction of each of the threads 1202a – e.g., the direction of the crescent of the thread 1202a – is substantially the same (e.g., facing the same direction). In some examples, the direction of each of the threads 1202b – e.g., the direction of the crescent of the thread 1202b – is substantially the same (e.g., facing the same direction). In some examples, the thread 1202a is facing in the same direction as that of the threads 1202b. In some examples, the threads 1202a face in the opposite direction as that of the threads 1202b. In some examples, the threads 1202a, 1202b can extend to substantially the same major diameter. In some examples, the threads 1202a, 1202b can extend to differing major diameters.

[0105] FIGURE 13 illustrates an example thread pattern 1300 of a fastener. The thread pattern 1300 can include, in general, alternating threads 1302a, 1302b with alternating height “V”-shapes. Specifically, the threads 1302a, 1302b can extend from a shaft. The threads1302a, 1302b extend along at least a portion of the shaft of the fastener. The thread 1302a can include an undercut surface 1304a (similar to the undercut surface 131 and / or the a convex undercut surfaces 141 both of FIGURES 2A–2D). The undercut surface 1304a can have any geometric shape with respect to the shaft, and / or any angle with respect to the shaft. In the illustrated example, the undercut surface 1304a forms a “V” shape / angle with respect to the shaft of the fastener. The thread 1302b can include an undercut surface 1304b (similar to the undercut surface 131 and / or the a convex undercut surfaces 141 both of FIGURES 2A–2D). The undercut surface 1304b can have any geometric shape with respect to the shaft, and / or any angle with respect to the shaft. In the illustrated example, the undercut surface 1304b forms a “V” shape / angle with respect to the shaft of the fastener. The thread 1302a can extend to a first major diameter, and the thread 1302b can extend to a second major diameter; with the first major diameter of the thread 1302a being greater than the second major diameter of the thread 1302b. In some examples, the threads 1302a, 1302b can extend to the same major diameter.

[0106] FIGURE 14 illustrates an example thread pattern 1400 of a fastener. The thread pattern 1400 can include, in general, a thread 1402 including polygon undercuts and a “v”- shaped undercuts. Specifically, the thread 1402 can extend from a shaft. The thread 4102 extends along at least a portion of the shaft of the fastener. The thread 1402 can include a polygon undercut surface 1404a (similar to the undercut surface 131 and / or the a convex undercut surfaces 141 both of FIGURES 2A–2D). The polygon undercut surface 1404a can have any geometric shape with respect to the shaft. The thread 1402 can include an undercut surface 1404b (similar to the undercut surface 131 and / or the a convex undercut surfaces 141 both of FIGURES 2A–2D). The undercut surface 1404b can have any geometric shape with respect to the shaft, and / or any angle with respect to the shaft. In the illustrated example, the undercut surface 1404b forms a “V” shape / angle with respect to the shaft of the fastener.

[0107] FIGURE 15 illustrates an example thread pattern 1500 of a fastener. The thread pattern 1500 can include, in general, threads 1502a, 1502b of hooks. Specifically, the threads 1502a, 1502b can extend from a shaft. The threads 1502a, 1502b extend along at least a portion of the shaft of the fastener. The thread 1502a can include a hook geometric shape – similar to the first helical pattern 110 and the second helical pattern 120. The thread 1502b can include a hook geometric shape – similar to the first helical pattern 110 and the second helical pattern 120. The threads 1502a can have a first spacing D1 distance between each other; and the threads 1502b can have the first spacing distance between each other. Further, the set of threads1502a can be spaced-apart from the set of threads 1504b a second distance D2. In some example, the second distance D2 is greater than the first distance D1.

[0108] FIGURE 16 illustrates an example thread pattern 1600 of a fastener. The thread pattern 1600 can include, in general, alternating threads 1602a, 1602b of hooks. Specifically, the threads 1602a, 1602b can extend from a shaft. The threads 1602a, 1602b extend along at least a portion of the shaft of the fastener. The thread 1602a can include a hook geometric shape – similar to the first helical pattern 110 and the second helical pattern 120. Further, the thread 1602a can include a rounded end 1604a. The thread 902b can include a hook geometric shape – similar to the first helical pattern 110 and the second helical pattern 120. Further, the thread 1602b can include a rounded end 1604b. In some examples, the threads 1602a, 1602b can extend to the same major diameter. In some examples, the thread 1602a can extend to a first major diameter, and the thread 1602b can extend to a second major diameter; with the first major diameter of the thread 1602a being greater than the second major diameter of the thread 1602b.

[0109] FIGURE 17 illustrates an example thread pattern 1700 of a fastener. The thread pattern 1700 can include, in general, alternating threads 1702a, 1702b of hooks. Specifically, the threads 1702a, 1702b can extend from a shaft. The threads 1702a, 1702b extend along at least a portion of the shaft of the fastener. The thread 1702a can include a hook geometric shape – similar to the first helical pattern 110 and the second helical pattern 120. The thread 1702a can include an undercut surface 1704a (similar to the undercut surface 131 and / or the a convex undercut surfaces 141 both of FIGURES 2A–2D). The undercut surface 1704a can have any geometric shape with respect to the shaft, and / or any angle with respect to the shaft. In the illustrated example, the undercut surface 1704a forms a “V” shape / angle with respect to the shaft of the fastener. The thread 1702b can include a hook geometric shape – similar to the first helical pattern 110 and the second helical pattern 120. The thread 1702b can include an undercut surface 1704b (similar to the undercut surface 131 and / or the a convex undercut surfaces 141 both of FIGURES 2A–2D). The undercut surface 1704b can have any geometric shape with respect to the shaft, and / or any angle with respect to the shaft. In the illustrated example, the undercut surface 1704b forms a “V” shape / angle with respect to the shaft of the fastener. The threads 1702a, 1702b can be positioned to form a “dovetail” therebetween. That is, the angle of the undercut surface 1704a is opposite and complimentary to that of the undercut surface 1704b. In some examples, the threads 1702a, 1702b can extend to the same major diameter. In some examples, the thread 1702a can extend to a first major diameter, and thethread 1702b can extend to a second major diameter; with the first major diameter of the thread 1702a being greater than the second major diameter of the thread 1702b.

[0110] FIGURE 18 illustrates an example thread pattern 1800 of a fastener. The thread pattern 1800 can include, in general, alternating threads 1802a, 1802b. Specifically, the threads 1802a, 1802b can extend from a shaft. The threads 1802a, 1802b extend along at least a portion of the shaft of the fastener. The thread 1802a can include a shaft portion 1804a and an extension portion 1806a. The thread 1802b can include a shaft portion 1804b and an extension portion 1806b. The extension portions 1806a, 1806b can extend towards one another. In some examples, the threads 1802a, 1802b can extend to the same major diameter. In some examples, the thread 1802a can extend to a first major diameter, and the thread 1802b can extend to a second major diameter; with the first major diameter of the thread 1802a being greater than the second major diameter of the thread 1802b.

[0111] FIGURE 19 illustrates an example thread pattern 1900 of a fastener. The thread pattern 1900 can include, in general, alternating threads 1902a, 1902b. Specifically, the threads 1902a, 1902b can extend from a shaft. The threads 1902a, 1902b extend along at least a portion of the shaft of the fastener. The threads 1902a, 1902b can be defined by recesses 1904a, 1904b, 1904c. Specifically, the thread 1902a can be defined by recesses 1904a, 1904b and the thread 1902b can be defined by recesses 1904b, 1904c. In some examples, the recesses 1904a, 1904b, 1904c can have a “lollipop” shape form.

[0112] FIGURE 20 illustrates an example thread pattern 2000 of a fastener. The thread pattern 2000 can include, in general, threads 2002a, 2002b, 2002c. Specifically, the threads 2002a, 2002b, 2002c can extend from a shaft. The threads 2002a, 2002b, 2002c can extend along at least a portion of the shaft of the fastener. The threads 2002a, 2002b, 2002c can include a hook geometric shape – similar to the first helical pattern 110 and the second helical pattern 120. In particular, the threads 2002a, 2002b, 2002c can have varying inflection points 2004a, 2004b, 2004c, respectively, that represent the separation of the first helical pattern 110 from the second helical pattern 120. The inflection points 2004a, 2004b, 2004c can vary for each thread 2002a, 2002b, 2002c and can alternate. In some examples, the threads 2002a, 2002b, 2002c can extend to the same major diameter

[0113] FIGURE 21 illustrates an example thread pattern 2100 of a fastener. The thread pattern 2100 can include, in general, thread 2102 of rounded posts. Specifically, the thread 2102 can extend from a shaft. The thread 2102 extends along at least a portion of the shaft of the fastener. The thread 2102 can include rounded posts – a post with a bulbous end.

[0114] FIGURE 22 illustrates an example thread pattern 2200 of a fastener. The thread pattern 2200 can include, in general, thread 2202 of “T”-shaped threads with hooks. Specifically, the thread 2202 can extend from a shaft. The thread 2202 extends along at least a portion of the shaft of the fastener. The thread 2202 can include “T”-shaped threads including hooks. The thread 2202 can include any hooking geometric shape, including a substantially 90 degree hook (from a body of the thread 2202) and a curved hooked (from a body of the thread 2202).

[0115] FIGURE 23 illustrates an example thread pattern 2300 of a fastener. The thread pattern 2300 can include, in general, thread 2302 of chamfered “T”-shaped threads. Specifically, the thread 2302 can extend from a shaft. The thread 2302 extends along at least a portion of the shaft of the fastener. The thread 2302 can include “T”-shaped threads including chamfered ends.

[0116] FIGURE 24 illustrates an example thread pattern 2400 of a fastener. The thread pattern 2400 can include, in general, thread 2402 of “V”-shaped threads with overhangs. Specifically, the thread 2402 can extend from a shaft. The thread 2402 extends along at least a portion of the shaft of the fastener. The thread 2402 can include “V”-shaped threads including overhangs.

[0117] FIGURE 25 illustrates an example thread pattern 2500 of a fastener. The thread pattern 2500 can include, in general, thread 2502 of hook / wave threads. Specifically, the thread 2502 can extend from a shaft. The thread 2502 extends along at least a portion of the shaft of the fastener. The thread 2502 can include a hook / wave geometry. The threads 2502 can include a curved portion positioned opposite to a facet portion.

[0118] FIGURE 26 illustrates an example thread pattern 2600 of a fastener. The thread pattern 2600 can include, in general, thread 2602 of offset “T”-shape threads. Specifically, the thread 2602 can extend from a shaft. The thread 2602 extends along at least a portion of the shaft of the fastener. The thread 2602 can include a “T”-shaped geometry that is offset (e.g., the post of the “T” is offset).

[0119] FIGURE 27 illustrates an example thread pattern 2700 of a fastener. The thread pattern 2700 can include, in general, thread 2702 of leaning square shaped hooks. Specifically, the thread 2702 can extend from a shaft. The thread 2702 extends along at least a portion of the shaft of the fastener. The thread 2702 can include hooks, that the posts are angled with respect to the shaft, and hooks are squared.

[0120] FIGURE 28 illustrates an example thread pattern 2800 of a fastener. The thread pattern 2800 can include, in general, thread 2802 of leaning hooks / barbs. Specifically, the thread 2802 can extend from a shaft. The thread 2802 extends along at least a portion of the shaft of the fastener. The thread 2802 can include hooks, that the posts are angled with respect to the shaft, and hooks are barbed.

[0121] FIGURE 29 illustrates an example thread pattern 2900 of a fastener. The thread pattern 2900 can include, in general, thread 2902 of diamonds on a post. Specifically, the thread 2902 can extend from a shaft. The thread 2902 extends along at least a portion of the shaft of the fastener. The thread 2902 can include a post with diamond shapes at an end thereof.

[0122] FIGURE 30 illustrates an example thread pattern 3000 of a fastener. The thread pattern 3000 can include, in general, thread 3002 of diamonds within a post. Specifically, the thread 3002 can extend from a shaft. The thread 3002 extends along at least a portion of the shaft of the fastener. The thread 3002 can include a post with diamond shapes positioned within a body of the post.

[0123] FIGURE 31 illustrates an example thread pattern 3100 of a fastener. The thread pattern 3100 can include, in general, thread 3102 of spheres (circles / teardrops). Specifically, the thread 3102 can extend from a shaft. The thread 3102 extends along at least a portion of the shaft of the fastener. The thread 3102 can include spherical based geometry – e.g., spheres, circles, teardrops.

[0124] FIGURE 32 illustrates an example thread pattern 3200 of a fastener. The thread pattern 3200 can include, in general, thread 3202. Specifically, the thread 3202 can extend from a shaft. The thread 3202 extends along at least a portion of the shaft of the fastener. The thread 3200 can include a hook geometric shape – similar to the first helical pattern 110 and the second helical pattern 120. Further, the thread 3202 can include an undercut surface 3204 (similar to the undercut surface 131 and / or the a convex undercut surfaces 141 both of FIGURES 2A–2D). The undercut surface 3204 can have a rounded or curved shape (e.g., with respect to the shaft). Further, the surface 3206 can have straight facets.

[0125] FIGURE 33 illustrates an example thread pattern 3300 of a fastener. The thread pattern 3300 can include, in general, thread 3302. Specifically, the thread 3302 can extend from a shaft. The thread 3302 extends along at least a portion of the shaft of the fastener. The thread 3302 can include a hook geometric shape – similar to the first helical pattern 110 and the second helical pattern 120. Further, the thread 3302 can include an undercut surface 3304 (similar to the undercut surface 131 and / or the a convex undercut surfaces 141 both ofFIGURES 2A–2D). The undercut surface 3304 can have any geometric shape with respect to the shaft, and / or any angle with respect to the shaft. Further, the surface 3306 can be curved or rounded (e.g., with respect to the shaft).

[0126] FIGURE 34 illustrates an example thread pattern 3400 of a fastener. The thread pattern 3400 can include, in general, thread 3402. Specifically, the thread 3402 can extend from a shaft. The thread 3402 extends along at least a portion of the shaft of the fastener. The thread 3402 can include a hook geometric shape – similar to the first helical pattern 110 and the second helical pattern 120. Further, the thread 3402 can include an undercut surface 3404 (similar to the undercut surface 131 and / or the a convex undercut surfaces 141 both of FIGURES 2A–2D). The undercut surface 3404 can have any geometric shape with respect to the shaft, and / or any angle with respect to the shaft. Further, the surface 3406 can have straight facets, and the surface 3408 can be curved or rounded (e.g., with respect to the shaft).

[0127] FIGURE 35 illustrates an example thread pattern 3500 of a fastener. The thread pattern 3500 can include, in general, thread 3502 of “waves”. Specifically, the thread 3502 can extend from a shaft. The thread 3502 extends along at least a portion of the shaft of the fastener. The thread 3502 can include a “wave” shaped geometry that are “leaning back”

[0128] FIGURE 36 illustrates an example thread pattern 3600 of a fastener. The thread pattern 3600 can include, in general, thread 3602. Specifically, the thread 3602 can extend from a shaft. The thread 3602 extends along at least a portion of the shaft of the fastener. The thread 3602 can include frustum or diamond-shaped squares.

[0129] FIGURE 37 illustrates an example thread pattern 3700 of a fastener. The thread pattern 3700 can include, in general, thread 3702. Specifically, the thread 3702 can extend from a shaft. The thread 3602 extends along at least a portion of the shaft of the fastener. The thread 3702 can include chamfered squares.

[0130] FIGURE 38 illustrates an example thread pattern 3800 of a fastener. The thread pattern 3800 can include, in general, thread 3802. Specifically, the thread 3802 can extend from a shaft. The thread 3802 extends along at least a portion of the shaft of the fastener. The thread 3802 can include double-chamfered squares.

[0131] FIGURE 39 illustrates an example thread pattern 3900 of a fastener. The thread pattern 3900 can include, in general, thread 3902. Specifically, the thread 3902 can extend from a shaft. The thread 3902 extend along at least a portion of the shaft of the fastener. The thread 3902 be defined by recesses 3904a, 3904b. In some examples, the recesses 3904a, 3904b can be curved.

[0132] FIGURE 40 illustrates an example thread pattern 4000 of a fastener. The thread pattern 4000 can include, in general, thread 4000. Specifically, the thread 4000 can extend from a shaft. The thread 4000 extends along at least a portion of the shaft of the fastener. The thread 4000 can include a square hook geometric shape.

[0133] FIGURE 41 illustrates an example thread pattern 4100 of a fastener. The thread pattern 4100 can include, in general, thread 4102. Specifically, the thread 4102 can extend from a shaft. The thread 4000 extends along at least a portion of the shaft of the fastener. The thread 4102 can include an inverted frustrum pyramid geometric shape.

[0134] FIGURE 42 illustrates an example thread pattern 4200 of a fastener. The thread pattern 4200 can include, in general, thread 4202. Specifically, the thread 4202 can extend from a shaft. The thread 4202 extend along at least a portion of the shaft of the fastener. The thread 4202 be defined by recesses 4204a, 4204b. In some examples, the recesses 4204a, 4204b can be keyhole pattern.

[0135] FIGURE 43 illustrates an example thread pattern 4300 of a fastener. The thread pattern 4300 can include, in general, thread 4302. Specifically, the thread 4302 can extend from a shaft. The thread 4302 extends along at least a portion of the shaft of the fastener. The thread 4302 can include a square hook geometric shape.

[0136] FIGURE 44 illustrates an example thread pattern 4400 of a fastener. The thread pattern 4400 can include, in general, thread 4402. Specifically, the thread 4402 can extend from a shaft. The thread 4402 extends along at least a portion of the shaft of the fastener. The thread 4402 can include a wave geometric shape.

[0137] FIGURE 45 illustrates an example thread pattern 4500 of a fastener. The thread pattern 4500 can include, in general, thread 4502. Specifically, the thread 4502 can extend from a shaft. The thread 4502 extends along at least a portion of the shaft of the fastener. The thread 4502 can include a double wave geometric shape.

[0138] FIGURE 46 illustrates an example thread pattern 4600 of a fastener. The thread pattern 4600 can include, in general, thread 4602. Specifically, the thread 4602 can extend from a shaft. The thread 4602 extends along at least a portion of the shaft of the fastener. The thread 4602 be defined by recesses 4604a, 4604b. In some examples, the recesses 4604a, 4604b can be curved / circular. In some examples, the thread 4602 can be flared

[0139] FIGURE 47 illustrates an example thread pattern 4700 of a fastener. The thread pattern 4700 can include, in general, thread 4702. Specifically, the thread 4702 can extendfrom a shaft. The thread 4702 extends along at least a portion of the shaft of the fastener. The thread 4702 can include a polygon geometric shape.

[0140] FIGURE 48 illustrates an example thread pattern 4800 of a fastener. The thread pattern 4800 can include, in general, thread 4802. Specifically, the thread 4802 can extend from a shaft. The thread 4802 extends along at least a portion of the shaft of the fastener. The thread 4802 can include a circular / spherical geometric shape.

[0141] FIGURE 49 illustrates an example thread pattern 4900 of a fastener. The thread pattern 4900 can include, in general, thread 4902 of “T”-shape threads. Specifically, the thread 4902 can extend from a shaft. The thread 4902 extends along at least a portion of the shaft of the fastener. The thread 4902 can include a “T”-shaped geometry.

[0142] FIGURE 50 illustrates an example thread pattern 5000 of a fastener. The thread pattern 5000 can include, in general, thread 5002. Specifically, the thread 5002 can extend from a shaft. The thread 5002 extends along at least a portion of the shaft of the fastener. The thread 5002 can include a dovetail geometric shape.

[0143] FIGURE 51 illustrates an example thread pattern 5102 of a fastener. The thread pattern 5102 can include, in general, thread 5102. Specifically, the thread 5102 can extend from a shaft. The thread 5102 extends along at least a portion of the shaft of the fastener. The thread 5102 can include a hook geometric shape.

[0144] FIGURE 52 illustrates an example thread pattern 5200 of a fastener. The thread pattern 5200 can include, in general, thread 5202. Specifically, the thread 5202 can extend from a shaft. The thread 5202 extends along at least a portion of the shaft of the fastener. The thread 5202 can include a hooking geometric shape.

[0145] FIGURE 53 illustrates an example thread pattern 5300 of a fastener. The thread pattern 5300 can include, in general, thread 5302. Specifically, the thread 5302 can extend from a shaft. The thread 5302 extends along at least a portion of the shaft of the fastener. The thread 5302 can include a wave geometric shape.

[0146] FIGURE 54 illustrates an example thread pattern 5400 of a fastener. The thread pattern 5400 can include, in general, thread 5402. Specifically, the thread 5402 can extend from a shaft. The thread 5402 extends along at least a portion of the shaft of the fastener. The thread 5402 can include a wave geometric shape.

[0147] FIGURE 55 illustrates an example thread pattern 5500 of a fastener. The thread pattern 5500 can include, in general, thread 5502. Specifically, the thread 5502 can extendfrom a shaft. The thread 5502 extends along at least a portion of the shaft of the fastener. The thread 5502 can include a hooking geometric shape.

[0148] FIGURE 56 illustrates an example thread pattern 5600 of a fastener. The thread pattern 5600 can include, in general, thread 5602. Specifically, the thread 5602 can extend from a shaft. The thread 5602 extend along at least a portion of the shaft of the fastener. The thread 5602 be defined by recesses 5604a, 5604b. In some examples, the recesses 5604a, 5604b can be keyhole pattern.

[0149] FIGURE 57 illustrates an example thread pattern 5700 of a fastener. The thread pattern 5700 can include, in general, thread 5702. Specifically, the thread 5702 can extend from a shaft. The thread 5702 extends along at least a portion of the shaft of the fastener. The thread 5702 can include a dovetail geometric shape with triangular protrusions.

[0150] FIGURE 58 illustrates an example thread pattern 5800 of a fastener. The thread pattern 5800 can include, in general, thread 5802. Specifically, the thread 5802 can extend from a shaft. The thread 5802 extends along at least a portion of the shaft of the fastener. The thread 5802 can include a dovetail geometric shape, with rounded triangular protrusions.

[0151] FIGURE 59 illustrates an example thread pattern 5900 of a fastener. The thread pattern 5900 can include, in general, threads 5902a, 5902b, 5902c, 5902d. Specifically, the thread 5902 can extend from a shaft (e.g., the shaft 105, the shank 250, the shaft 313). The thread 5902 extends along at least a portion of the shaft of the fastener. The thread 5902 can include a leaning square hook with variations of curvature.

[0152] FIGURE 60 illustrates an example thread pattern 6000 of a fastener. The thread pattern 6000 can include, in general, threads 6002a, 6002b, 6002c, 6002d (collectively referred to as threads 6002). Specifically, the thread 6002 can extend from a shaft. The thread 6002 extends along at least a portion of the shaft of the fastener. The thread 6002 can include a leaning rounded hook with variations of curvature.

[0153] Any of the thread patterns and threads may be combined in any combination to form any variation of the fastener.

[0154] FIGURE 61 illustrates a system 6100 for forming a fastener (e.g., any of fastener 1, fastener 100, fastener 300) having any of the thread patterns described herein. The system 6100 can include a forming die, a rolling die, and a steel ribbon roll.

[0155] Specifically, the system 6100 can facilitate creation of a multiangle threadform screw device (e.g., fastener 100) where threads are formed by extrusion dies and attached by spiral welding. This device can contain at least one multiangle threadform and may alsocontain a second threadform in an opposite orientation than the first. The combination of roll forming dies, bead roller technology or radius edge dies, and spiral welding manufacturing process enables the creation of the threadforms on a ground screw or pile in a large form factor device (e.g., 3–5 foot). This unique device with threadform creates instant stability into the substrate (dirt, concrete, sand, clay or other terrestrial materials) and enables stability even in off-axis loading conditions. Additional roll forming dies, bead roller technology or radius edge dies are used to transform steel ribbon to multi-angle profile before integration onto steel tube via spiral welding technique.

[0156] The ground screw or pile device can be used in the construction industry for fences, terraces, barns / sheds, piers & docks, road signs, solar panels, storage hangars or other outdoor structures where a support post is needed and unleveled ground may be present. The threadform formation process using dies and spiral welding manufacturing process enables a high volume production process of this multiangle threadform device. This novel device enables improved structural integrity and off-axis loading for these applications.

[0157] Novel threadforms that have shown off-axis stability by integration and preservation of the substrate is critical for strong foundational integrity. The creation of these multi-angle threadforms through the use of rolling or forming dies with the integration onto a post via spiral welding has enabled a new device that creates a new performance standard.

[0158] FIGURES 62–67 illustrates a multi-step process to create the threadform with flat, planetary, and cylindrical dies. First, as the fixed die and translational die squeeze the cold headed fastener shank, an initial profile will be created with a downward angle and the overall dimensions of the final or modified thread. In the second step, the initial thread profile will be shaped at another angle less than 180 degrees from normal to create the final or modified multi- angle thread profile. Further, a multiangle threadform device is created where threads are formed by flat, planetary or cylindrical dies in a single or multi step process. This process creates at least one multiangle threadform on a device and may also contain a second threadform in an opposite orientation than the first. The threadform manufacturing process using flat, planetary or cylindrical dies can form fasteners that have work hardened threads, unique undercut thread, lower cost than machining and enable high throughput processing. The novel two-stage manufacturing process to create the threads is part of the fastener formation process. A multi-step process to form threads using dies that create threads that are not perpendicular to the shank of the fastener. This process enables a non-perpendicular thread geometry in the initial profile and then a bent or angled tooth remaining in the finalconfiguration. Novel threadforms that have shown off-axis stability by integration and preservation of the substrate is needed for strong foundational integrity. The creation of these multi-angle threadforms through the use of flat, planetary or cylindrical dies enabled a new device that creates a new performance standard.

[0159] Specifically, FIGURES 62A–62F illustrates a first stage using a fixed die 6202 and a translation die 6204 to form a thread pattern on a fastener 6206 (e.g., any of fastener 1, fastener 100, fastener 300). In some examples, the first stage forms a first helical thread on the fastener 6206 (e.g., the first helical thread 110). Further, FIGURES 63A–63D illustrates a second stage a cylindrical die 6302 to modifying the thread pattern on the fastener 6206 (e.g., any of1, fastener 100, fastener 300). In some examples, the second stage forms a second helical thread on the fastener 6206 (e.g., the second helical thread 120). In a further implementation, FIGURES 66A–66C illustrate an alternative second stage using a fixed die 6602 and a translation die 6604 to form a thread pattern on the fastener 6206 (e.g., any of fastener 1, fastener 100, fastener 300). In some examples, the alternative second stage forms a second helical thread on the fastener 6206 (e.g., the second helical thread 120).

[0160] In a further implementation, FIGURES 64A–64C illustrate an alternative first stage using cylindrical dies 6402 to form a thread pattern on the fastener 6206 (e.g., any of fastener 1, fastener 100, fastener 300). In some examples, the alternative first stage forms a first helical thread on the fastener 6206 (e.g., the first helical thread 110). Further, FIGURES 65A–65C illustrate an alternative second stage using cylindrical die 6502 to modify the thread pattern on the fastener 6206 (e.g., any of fastener 1, fastener 100, fastener 300). In some examples, the alternative second stage forms a second helical thread on the fastener 6206 (e.g., the second helical thread 120).

[0161] FIGURES 67A–67D illustrate a multi-step process create the threadform using a fixed die 6702 and a translation die (similar to the translation die 6204). The fixed die 6702 can including a thread bending feature 6706 at the end of the fixed die 6702.

[0162] FIGURES 68A–68E illustrate a fastener 6802. The fastener 6802 can be an “ice screw” that is used as anchor to ice while ice climbing.

[0163] The fastener 6802 can include a tubular screw body 6803 (e.g., the shank 6, the shaft 105, the shaft 313) with external threads. A hanger 6804 for use with carabiners is attached to the head of the fastener 6802 and is also used as a handle for insertion. The tip of the fastener 6802 is self-drilling and self-tapping, Displaced ice from insertion is evacuated via the internal bore of the fastener 6802. Materials that may be used for the fastener 6802 andhanger are aluminum, titanium, stainless steel, or other steel alloys. A combination of materials may be used. Anodizing, plating, or other coating may be applied for rust prevention. Manufacturing methods for the fastener 6802 may include machining or 3D printing. The hanger 6804 may be machined, forged, stamped, or 3D printed.

[0164] Ice screws are placed in ice to be anchors for ice climbing. Using the attached hanger and / or handle, they are screwed into ice for use, and then removed when no longer needed. Ropes and other safty equipment is attached via carabiners to the screw’s hanger to protect the climber. Ice screws are re-useable. The self tapping and self drilling features enable use without other tools. The ice screws can have better insertion properties along with better integration to the ice will result in a safer anchor. Ice quality and strength varies and a better interface with the ice can provide a stronger anchor point.

[0165] In some further implementations, any of the fasteners described herein with any of the thread patterns described herein can be used as a multiple angle threadform staking device. Specifically, stakes are used to hold items in place and typically, the stakes are placed in terrestrial materials such as dirt, clay, sand or ice to hold items like tents, umbrellas or canopies. A multiangle threadform staking device that integrates the stake directly into ground-based substrates are utilized for increased primary fixation and off-axis loading when in use. The threadform will also improve the ease of insertion into hard packed material like clay, compacted soil or ice. This device will contain at least one multiangle threadform and may also contain a second threadform in an opposite orientation than the first.

[0166] The ground stakes can have a multi-angle threadform on the shaft of the device (similar to any thread pattern described herein), an attachment feature at the top of the stake to secure ropes, ties or other binding materials and a shaft that is tapered to a point. Additional embodiments may include a hollow stake with multi-angle threads on the exterior shaft for use in mounting in a less stable substrate. These stakes may be made with traditional manufacturing processes like metal casting, machining, spiral welding, 3D printing or injection molding. These stakes may be made out of metal, polymers or plastics.

[0167] The stake device can be used in the recreation and sporting goods industry for securing tents, canopies, umbrellas, tarps and other items used outdoors where fixation of an item to the ground is required. The unique threadform enables integration into a variety of substrates such as soil, clay, sand, ice. This novel device enables improved structural integrity and off-axis loading for these applications where non-predictable environmental events can cause loading of the ground stake. The integration of the unique threadform on a ground stakedevice that is between 6–18” in length. This unique device with threadform as discussed herein creates instant stability into the substrate (soil, ice, sand, or clay) and enables stability even in off-axis loading conditions. The threadforms as discussed herein have shown off-axis stability by integration and preservation of the substrate is critical for strong foundational integrity. The creation of these multi-angle threadforms through the use of traditional manufacturing routes have enabled a new device that creates a new performance standard.

[0168] In some further implementations, any of the fasteners (e.g., any of fastener 1, fastener 100, fastener 300) described herein having any of the thread patterns described herein can be manufactured using one or more of cold heading / forming, milling, machining, molding, additive material (3D Printing), flat, planetary or round external thread rolling dies, spiral welding, or investment casting. Any of the fasteners (e.g., any of fastener 1, fastener 100, fastener 300) described herein having any of the thread patterns described herein can be formed of such materials as metals (aluminum, steel, nickel, titanium, etc.), metal alloys, plastics and polymers (polyethylene, polypropylene, polycarbonate, etc.), ceramics, or composite materials. Any of the fasteners (e.g., any of fastener, fastener 100, fastener 300) described herein having any of the thread patterns described herein can have any of the features including flat tip, pointed tip, self-tapping tip, cannulation, head, no head, buttress threaded insert, locking nut, partially threaded bolt, dual / tri / quad UnifiMI threads, concave threads, convex threads, fixed major diameter, variable major diameter, various pitch thread forms. Any of the fasteners (e.g., any of fastener 1, fastener 100, fastener 300) described herein having any of the thread patterns described herein can be used in substrates such as stone, ice, metal or metal alloys, wood, composites, ceramic, plastic, concrete, fibrous or woven, polymer or plastic.

[0169] Any of the fasteners (e.g., any of fastener 1, fastener 100, fastener 300) described herein having any of the thread patterns described herein can be used in such implementations as threaded fastener: single and dual threaded fastener with and without tapping; headless threaded fastener: single and dual threaded fastener with and without tapping; bolt and nut: single and dual threaded fastener; insert nut: outside fastener, inside standard or metric; tapping bit: single and dual threaded fastener to tap solid material; threaded clip; double ended threaded stud for soft materials: single threaded fastener on one end, standard or metric thread on other; threaded screw with post for over molding; and drill bit for round holes in metal, plastic, concrete, wood, composite, or multi-material.

[0170] The above disclosed subject matter is to be considered illustrative, and not restrictive, and the appended claims are intended to cover all such modifications,enhancements, and other embodiments which fall within the true spirit and scope of the present disclosure. Thus, to the maximum extent allowed by law, the scope of the present disclosure is to be determined by the broadest permissible interpretation of the following claims and their equivalents, and shall not be restricted or limited by the foregoing detailed description.

[0171] Herein, “or” is inclusive and not exclusive, unless expressly indicated otherwise or indicated otherwise by context. Therefore, herein, “A or B” means “A, B, or both,” unless expressly indicated otherwise or indicated otherwise by context. Moreover, “and” is both joint and several, unless expressly indicated otherwise or indicated otherwise by context. Therefore, herein, “A and B” means “A and B, jointly or severally,” unless expressly indicated otherwise or indicated otherwise by context.

[0172] The scope of this disclosure encompasses all changes, substitutions, variations, alterations, and modifications to the example embodiments described or illustrated herein that a person having ordinary skill in the art would comprehend. The scope of this disclosure is not limited to the example embodiments described or illustrated herein. Moreover, although this disclosure describes and illustrates respective embodiments herein as including particular components, elements, features, functions, operations, or steps, any of these embodiments may include any combination or permutation of any of the components, elements, features, functions, operations, or steps described or illustrated anywhere herein that a person having ordinary skill in the art would comprehend. Furthermore, reference in the appended claims to an apparatus or system or a component of an apparatus or system being adapted to, arranged to, capable of, configured to, enabled to, operable to, or operative to perform a particular function encompasses that apparatus, system, or component, whether or not it or that particular function is activated, turned on, or unlocked, as long as that apparatus, system, or component is so adapted, arranged, capable, configured, enabled, operable, or operative.

Claims

WHAT IS CLAIMED IS:

1. A method of manufacturing a fastener, the method comprising: contacting at least one first-stage die to the fastener to form an initial helical threadform disposed about a shaft of the fastener; and contacting at least one second-stage die to the fastener to deform the initial helical threadform, thus forming a modified helical threadform, 2. The method of claim 1 wherein the modified helical threadform is formed by creating at least one bend in the initial helical threadform.

3. The method of claim 1 wherein the at least one first-stage die comprises a flat first- stage fixed die and a flat first-stage translational die, wherein the first-stage fixed die remains stationary while the first-stage translational die moves, rolling the fastener across both the first-stage fixed die and the first-stage translational die during forming of the initial helical threadform.

4. The method of claim 1, 2, or 3 wherein the at least one second-stage die comprises an internal cylindrical die into which the fastener is inserted during forming the modified helical threadform.

5. The method of claim 1, 2, or 3 wherein the at least one second-stage die comprises a flat second-stage fixed die and a flat second-stage translational die, wherein the second- stage fixed die remains stationary while the second-stage translational die moves, rolling the fastener across both the second-stage fixed die and the second-stage translational die during forming of the modified helical threadform.

6. The method of claim 1 wherein the at least one first-stage die comprises two or more external cylindrical cutting dies, wherein the fastener is rolled between the external cylindrical cutting dies to form the initial helical threadform.

7. A method of manufacturing a fastener, the method comprising:contacting at least one die to the fastener, wherein at least a selected die from the at least one dies is a two-stage die comprising distinct first and second portions, the first and second die portions comprising differing features; wherein: the fastener is contacted to the first portion of the selected die during an initial formation of an initial helical threadform disposed about a shaft of the fastener; and the fastener is contacted to a second portion of the same selected die during a deformation stage, wherein during the deformation stage the initial threadform is deformed to create a modified helical threadform.

8. The method of claim 7, wherein the selected two-stage die is a flat die.

9. The method of claim 8 further comprising a second flat die of the at least one two- stage dies, wherein the selected two-stage die is a fixed die and the second flat die is a translational die, wherein the selected die remains stationary while the second die moves, rolling the fastener across both the selected and second dies during forming of the initial helical threadform and during forming the modified helical threadform.

10. The method of claim 8 further comprising a second flat die of the at least one two- stage dies, wherein the second die is a fixed die and the selected two-stage flat die is a translational die, wherein the second die remains stationary while the selected two-stage die moves, rolling the fastener across both the selected and second dies during forming of the initial helical threadform and during forming the modified helical threadform.

11. The method of claim 7, wherein the selected two-stage die is an external cylindrical die.

12. The method of claim 11 wherein the fastener is rolled between the selected two- stage die and one or more additional dies of the at least one dies.

13. The method of claim 1 or 7 wherein the modified helical threadform comprises a plurality of first concave undercut surfaces and a plurality of first convex undercut surfaces. 14 The method of claim 13 wherein the first concave undercut surface is oriented facing a distal end of the fastener; and the first convex undercut surface is oriented facing a proximal end of the fastener.

15. The method of claim 13 wherein the first concave undercut surface is oriented facing a proximal end of the fastener; and the first convex undercut surface is oriented facing a distal end of the fastener.

16. The method of claim 13 wherein the modified helical threadform further comprises a plurality of second concave undercut surfaces and a plurality of second convex undercut surfaces.

17. The method of claim 14 wherein the plurality of first concave undercut surfaces is oriented in an opposing direction to the plurality of second concave undercut surfaces; and the plurality of first convex undercut surfaces is oriented in an opposing direction to the plurality of second convex surfaces.

18. The method of claim 1 or 7 wherein the fastener is initially manufactured using one or technique chosen from: cold heading; milling; molding; 3D printing; flat, planetary, or round external thread rolling dies; spiral welding; and investment casting.