RESILIENT FASTENER SYSTEM AND RESILIENT FASTENER INSERT

Abstract

A fastener insert includes a hollow shaft extending in an axial direction. The hollow shaft is configured to receive a threaded fastener at a first axial end of the hollow shaft. The fastener insert also includes a supporting flange extending radially outward from a second axial end of the hollow shaft. The hollow shaft includes an internally threaded shaft portion. The internally threaded shaft portion is configured to secure the threaded fastener received in the hollow shaft. The hollow shaft also includes a resilient shaft portion formed as a unitary single piece with the internally threaded shaft portion.

Claims

1. A fastener insert, comprising: a hollow shaft extending in an axial direction and configured to receive a threaded fastener at a first axial end of the hollow shaft; and a supporting flange extending radially outward from a second axial end of the hollow shaft; wherein the hollow shaft includes: an internally threaded shaft portion, the internally threaded shaft portion being configured to secure the threaded fastener received in the hollow shaft, and a resilient shaft portion formed as a unitary single piece with the internally threaded shaft portion.

2. The fastener insert of claim 1, wherein the resilient shaft portion is formed between the internally threaded shaft portion of the hollow shaft and the supporting flange.

3. The fastener insert of claim 1, wherein the resilient shaft portion is formed by at least one cutout in the hollow shaft.

4. The fastener insert of claim 3, wherein the at least one cutout includes a plurality of cutouts arranged circumferentially around the hollow shaft.

5. The fastener insert of claim 3, wherein at least one of the at least one cutout is triangular in shape.

6. The fastener insert of claim 3, wherein at least one of the at least one cutout is circular in shape.

7. The fastener insert of claim 3, wherein at least one of the at least one cutout is linear in shape.

8. The fastener insert of claim 1, wherein a thickness of a circumferential wall of the resilient shaft portion is less than a thickness of the circumferential wall of the internally threaded shaft portion.

9. The fastener insert of claim 1, wherein a circumferential wall of the resilient shaft portion is axially corrugated.

10. A fastener system, comprising: a fastener insert including: a hollow shaft extending in an axial direction from a first axial end to a second axial end of the hollow shaft, and a supporting flange extending radially outward from the second axial end of the hollow shaft; wherein the hollow shaft includes an internally threaded shaft portion and a resilient shaft portion formed as a unitary single piece with the internally threaded portion; and a fastener having a threaded shaft received in the hollow shaft of the fastener insert at the first axial end and secured to the internally threaded shaft portion of the hollow shaft.

11. The fastener system of claim 10, wherein a length of the threaded shaft of the fastener is less than or equal to a length of the internally threaded shaft portion of the hollow shaft of the fastener insert.

12. The fastener system of claim 10, wherein a length of the threaded shaft of the fastener is greater than a length of the internally threaded shaft portion of the hollow shaft of the fastener insert and equal to or less than a length of the hollow shaft of the fastener insert.

13. The fastener system of claim 10, wherein the resilient shaft portion is formed between the internally threaded shaft portion of the hollow shaft and the supporting flange.

14. The fastener system of claim 1, wherein the resilient shaft portion is formed by at least one cutout in the hollow shaft.

15. The fastener system of claim 14, wherein the at least one cutout is at least one of triangular, circular, and linear in shape.

16. The fastener system of claim 10, wherein a thickness of a circumferential wall of the resilient shaft portion is less than a thickness of the circumferential wall of the internally threaded shaft portion.

17. The fastener system of claim 10, wherein a circumferential wall of the resilient shaft portion is axially corrugated.

18. A method of fastening at least two elements together, the method comprising the steps of: inserting a first axial end of a hollow shaft of a fastener insert into a through hole extending through the at least two elements such that a supporting flange extending radially outward from a second axial end of the hollow shaft abuts an outer surface of a first element of the at least two elements; inserting a threaded shaft of a fastener into the first axial end of the hollow shaft and securing the threaded shaft of the fastener into an internally threaded shaft portion of the hollow shaft such that a head of the fastener abuts an outer surface of a second element of the at least two elements; and further securing the threaded shaft of the fastener into the internally threaded shaft portion of the hollow shaft such that tension is created on a resilient shaft portion of the hollow shaft, the resilient shaft portion of the hollow shaft being formed as a unitary single piece with the internally threaded shaft portion of the hollow shaft.

19. The method of claim 18, further comprising the step of accommodating for an axial thermal expansion of at least one of the fastener, the fastener insert, and at least one of the at least two elements when exposed to a change in temperature.

20. The method of claim 19, wherein the accommodating includes axially deforming the resilient shaft portion of the hollow shaft when the at least one of the fastener, the fastener insert, and at least one of the at least two elements undergoes the axial thermal expansion.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0028] The annexed drawings show various aspects of the disclosure.

[0029] FIG. 1 is a perspective view of a fastener system configured to fasten at least two elements, shown in cross-section.

[0030] FIG. 2A is a perspective view of a fastener insert of a fastener system.

[0031] FIG. 2B is a side view of the fastener insert of FIG. 2A.

[0032] FIG. 2C is another side view of the fastener insert of FIG. 2A.

[0033] FIG. 3A is a perspective view of another fastener insert of a fastener system.

[0034] FIG. 3B is a side view of the fastener insert of FIG. 3A.

[0035] FIG. 3C is cross-sectional side view of the fastener insert of FIG. 3A.

[0036] FIG. 4A is a perspective view of another fastener insert of a fastener system.

[0037] FIG. 4B is a side view of the fastener insert of FIG. 4A.

[0038] FIG. 4C is a cross-sectional side view of the fastener insert of FIG. 4A.

[0039] FIG. 5A is a perspective view of another fastener insert of a fastener system.

[0040] FIG. 5B is a side view of the fastener insert of FIG. 5A.

[0041] FIG. 5C is a cross-sectional side view of the fastener insert of FIG. 5A.

[0042] FIG. 6A is a perspective view of another fastener insert of a fastener system.

[0043] FIG. 6B is a side view of the fastener insert of FIG. 6A.

[0044] FIG. 6C is a cross-sectional side view of the fastener insert of FIG. 6A.

[0045] FIG. 7 is a flowchart of a method for fastening at least two elements together.

DETAILED DESCRIPTION

[0046] Described herein is fastener system for fastening at least two elements together. The fastener system includes a fastener and a fastener insert which is configured to accommodate for thermal expansion of at least one of the fastener, the fastener insert, or at least one of the at least two elements which are fastened together with the fastener system, when they are subjected to changes in temperature. Specifically, the fastener insert includes a resilient shaft portion that is configured to deform in the axial direction so that it can accommodate any such thermal expansion. The resilient shaft portion of the fastener insert is continuous, unitary and formed as a single piece with an internally threaded shaft portion that is configured to secure the fastener to the fastener insert. With the accommodation of thermal expansion by the resilient shaft portion of the fastener insert, a clamping force of the fastener system on the at least two elements being fastened therewith is effectively maintained throughout variable thermal expansion of at least one of the fastener, the fastener insert, or at least one of the at least two elements.

[0047] Turning to FIG. 1, an exemplary fastener system 10 will be described in more detail. The fastener system 10 is configured to fasten at least two elements, including a first element 12 and a second element 14, together. The fastener system 10 includes a fastener 16 and a fastener insert 18. The fastener system 10 may be used, for example, in any environment that experiences extreme changes in temperature, such as on hypersonic missiles and gas turbine engines, as non-limiting examples. Therefore, for example, the first element 12 and the second element 14 may include components on a hypersonic missile airframe such as flanges, control surfaces and leading-edge attachments which may be exposed to temperatures up to or exceeding 3,000° F., or components of a gas turbine engine such as gas turbine engine panels and bracket attachments which may be exposed to temperatures up to or exceeding 1,000° F. A thickness of the at least two elements in an axial direction 22, when fastened together, may be in a range of 0.64 centimeters (0.25 inch) to 15.24 centimeters (6 inches) for example 2.16 centimeters (0.85 inches). It will be understood, however, that these specific thicknesses, environments and examples of the first element 12 and the second element 14 are provided as non-limiting examples, and that the fastener system 10 described herein may be applicable to other environments that experience extreme changes in temperature, and the first element 12 and the second element 14 that the fastener system 10 is configured to fasten together may be of another size and may be any other fastened components in those environments.

[0048] The fastener insert 18 includes a hollow shaft 20 configured to extend in the axial direction 22 through a through hole 24 of the at least two elements, including the first element 12 and the second element 14. The hollow shaft 20 has a first axial end 26 and a second axial end 28 and may be cylindrical in shape. A length of the hollow shaft 20 in the axial direction may be in the range of 0.64 centimeters (0.25 inches) to 15.24 centimeters (6.0 inches), for example 1.65 centimeters (0.65 inches). An internal diameter of the hollow shaft 20 may be in the range of 0.48 centimeters (0.19 inches) to 2.54 centimeters (1 inch), for example 0.79 centimeters (0.31 inches). The fastener insert 18 also includes a supporting flange 30 extending radially outward from the second axial end 28 of the hollow shaft 18 such that when the first axial end 26 of the hollow shaft 18 is inserted into the through hole 24, the supporting flange 30 abuts an outer surface 32 of the first element 12. A diameter of the supporting flange 30 may be in the range of 0.64 centimeters (0.25 inch) to 7.62 centimeters (3 inches), for example 1.91 centimeters (0.75 inches). As will be described in more detail with reference to FIGS. 2A-6C, the hollow shaft 20 includes an internally threaded shaft portion 34 and a resilient shaft portion 36 formed as a unitary single piece with the internally threaded shaft portion 34. The resilient shaft portion 36 may be formed between the internally threaded shaft portion 34 of the hollow shaft 20 and the supporting flange 30. In general, a length of the internally threaded shaft portion 34 may be in the range of 0.48 centimeters (0.19 inch) to 14.61 centimeters (5.75 inches), for example 1.65 centimeters (0.65 inches), and a length of the resilient shaft portion 36 may be in the range of 0.16 centimeters (0.06 inch) to 13.97 centimeters (5.5 inches), for example 0.51 centimeters (0.20 inches). It will be understood, however, that the dimensions of the fastener insert 18 described herein are provided as non-limiting examples, and that other dimensions may be applicable to the fastener insert 18 depending on the environment and application in which it is used.

[0049] The fastener 16 is a threaded fastener having a head 38 and a threaded shaft 40 extending in the axial direction 22 from the head 38. The hollow shaft 20 of the fastener insert 18 is configured to receive the threaded shaft 40 of the fastener 16 at the first axial end 26 of the hollow shaft 20. Accordingly, a diameter of the threaded shaft 40 of the fastener 16 may correspond to the inner diameter of the hollow shaft 20 and may therefore be in a range of 0.48 centimeters (0.19 inch) to 2.54 centimeters (1 inch), for example 0.79 centimeters (0.31 inches). As with the dimensions of the hollow shaft 20, however, it is understood that the dimensions of the fastener 16 described herein are provided as non-limiting examples, and other dimensions of the fastener 16 may be applicable. The internally threaded shaft portion 34 of the hollow shaft 20 is configured to secure the threaded shaft 40 of the fastener 16 such that the head 38 of the fastener abuts an outer surface 42 of the second element 14. The threaded shaft 40 of the fastener 16 may have a length sufficient to ensure a strong and secure connection between the fastener 16 and the internally threaded shaft portion 34 of the hollow shaft 20 of the fastener insert 18 when the threaded shaft 40 is secured by the internally threaded shaft portion 34. That is, the length of the threaded shaft 40 may be less than or equal to a length of the internally threaded shaft portion 34 of the hollow shaft 20 of the fastener insert 18. However, the length of the threaded shaft 40 may alternatively be greater than the length of the internally threaded shaft portion 34 of the hollow shaft 20. In either case, the length of the threaded shaft 40 may be equal to or less than a length of the hollow shaft 20 of the fastener insert 18.

[0050] When the threaded shaft 40 of the fastener 16 is further secured in the internally threaded portion 34 of the hollow shaft 20 of the fastener insert 18, with the supporting flange abutting the outer surface 32 of the first element 12 and the head 38 of the fastener 16 abutting the outer surface 42 of the second element 14, an axial preloaded tension is created on the resilient shaft portion 36 of the hollow shaft 20 of the fastener insert 18. This tension imparts a clamping force on the at least two elements including the first element 12 and the second element 14, fastening the at least two elements together. As will be described in more detail below, due to the resiliency of the resilient shaft portion 36 (in particular, the ability of the resilient shaft portion 36 to deform in the axial direction), the clamping force is a resilient clamping force that accommodates axial thermal expansion of at least one of the fastener 16, the fastener insert 18 and at least one of the at least two elements (e.g., the first element 12 and/or the second element 14).

[0051] The fastener insert 18 is configured to have adequate strength to support an axial preloaded tension in order to achieve the required clamping force on the at least two elements 12, 14. As the axial preloaded tension may be sustained at elevated temperatures, the fastener insert 18 may be made with a suitable high temperature/high strength material. For example, for temperatures up to approximately 3,000° F., the fastener insert 18 may be made with ultra-high temperature ceramics (UHTC’s) and/or refractory metals such as tungsten, molybdenum alloys (e.g., TZM), columbium (niobium), and/or tantalum alloys. For temperatures up to approximately 1,800° F., the fastener insert 18 may be made with nickel super alloys such as Inconel. For temperatures up to approximately 1,200° F., the fastener insert 18 may be made with titanium and/or stainless-steel alloys. Each of these materials have coefficients of thermal expansion (CTE’s) in an approximate range of 3 to 10 micro-in/in/°F. This can exceed the CTE’s of the at least two elements, including the first element 12 and the second element 14, which are fastened together. For example, for high temperature applications, the at least two elements may be anisotropic ceramic matrix composite materials (CMC’s). It will be understood, however, that the specific materials and CTE’s described above are provided as non-limiting examples, and that other materials and CTE’s may be applicable to the fastener insert 18 depending on the environment and application for which it is used.

[0052] The resilient shaft portion 36 of the hollow shaft 20 of the fastener insert 18 may have a variety of forms that allow it to sustain the axial preloaded tension and make it deformable in the axial direction. For example, with reference to FIG. 2A to FIG. 4C, the resilient shaft portion 36 may be formed with at least one cutout 44 in the hollow shaft 20. The at least one cutout 44 is formed through a circumferential wall 46 of the resilient shaft portion 36. The at least one cutout 44 may include a plurality of cutouts 44 arranged circumferentially around the circumferential wall 46 of the resilient shaft portion 36 of the hollow shaft 20. As depicted in FIGS. 2A-C, at least one of the at least one cutout 44 may be triangular in shape. As depicted in FIGS. 3A-C, at least one of the at least one cutout 44 may be circular in shape. As depicted in FIGS. 4A-C, at least one of the at least one cutout 44 may be linear in shape. It will be understood that the shape, number and arrangements of the cutouts 44 described and depicted herein are provided as non-limiting examples and that other shapes, numbers and arrangements of cutouts 44 may be applicable to the resilient shaft portion 36 of the hollow shaft 20 to make it deformable in the axial direction. For example, in any embodiment, one or more deformable portions 48 of the resilient shaft portion 36 are created between the at least one cutout 44. The deformable portions 48 are deformable in the axial direction such that the resilient shaft portion 36 is deformable in the axial direction and can accommodate for axial thermal expansion of at least one of the fastener 16, the fastener insert 18 and at least one of the at least two elements 12, 14 when exposed to a change in temperature.

[0053] Additionally or alternatively, the circumferential wall 46 of the resilient shaft portion 36 may be formed to have different properties than a circumferential wall 50 of the internally threaded shaft portion 34 of the hollow shaft 20 that make it deformable in the axial direction. For example, with reference to FIGS. 5A-C, the circumferential wall 46 of the resilient shaft portion 36 may have a thickness that is less than a thickness of the circumferential wall 50 of the internally threaded shaft portion 34. The thickness of the circumferential wall 46 of the resilient shaft portion 36 may be in a range of 0.03 centimeters (0.01 inch) to 0.32 centimeters (0.125 inch). The thickness of the circumferential wall 50 of the internally threaded shaft portion 34 may be in a range of 0.089 centimeters (0.035 inch) to 0.635 centimeters (0.25 inch). In an embodiment, for example, the thickness of the circumferential wall 46 of the resilient shaft portion 36 may be approximately 10-15% of the diameter of the internally threaded shaft portion 34. Accordingly, the circumferential wall 46 of the resilient shaft portion 36 may be weaker and less rigid than the circumferential wall 50 of the internally threaded shaft portion 34 such that it can deform in the axial direction. Additionally or alternatively, as depicted in FIGS. 6A-C, the circumferential wall 46 of the resilient shaft portion 36 may be axially corrugated, or may have alternating areas of reduced thickness and increased thickness extending along the axial direction. Accordingly, the circumferential wall 46 of the resilient shaft portion 36 may deform in the axial direction.

[0054] With reference to FIG. 7, a method 100 of fastening at least two elements together is depicted. The method 100 includes a step 102 of inserting a first axial end of a hollow shaft of a fastener insert into a through hole extending through the at least two elements such that a supporting flange extending radially outward from a second axial end of the hollow shaft abuts an outer surface of the first element of the at least two elements. The at least two elements may be the same as the at least two elements previously described, including the first element 12 and the second element 14, and the fastener insert may be the same as the fastener insert 18 previously described, including the hollow shaft 20 and the supporting flange 30. The method 100 then includes a step 104 of inserting a threaded shaft of a fastener into the first axial end of the hollow shaft and securing the threaded shaft of the fastener into an internally threaded shaft portion of the hollow shaft such that a head of the fastener abuts an outer surface of the second element of the at least two elements. The fastener may be the same as the fastener 16 previously described.

[0055] The method 100 then includes a step 106 of further securing the threaded shaft of the fastener into the internally threaded shaft portion of the hollow shaft such that tension is created on a resilient shaft portion of the hollow shaft. The resilient shaft portion of the hollow shaft is formed as a unitary single piece with the internally threaded shaft portion of the hollow shaft, as described previously with the resilient shaft portion 36 and the internally threaded shaft portion 34 of the hollow shaft 20. The tension imparts a resilient clamping force on the at least two elements.

[0056] The method 100 may therefore include accommodating for an axial thermal expansion of at least one of the fastener, the fastener insert, and at least one of the at least two elements when exposed to a change in temperature. The accommodating includes axially deforming the resilient shaft portion of the hollow shaft when the at least one of the fastener, the fastener insert, and at least one of the at least two elements undergoes the axial thermal expansion.

[0057] Although the above disclosure has been shown and described with respect to a certain preferred embodiment or embodiments, it is obvious that equivalent alterations and modifications will occur to others skilled in the art upon the reading and understanding of this specification and the annexed drawings. In particular regard to the various functions performed by the above described elements (components, assemblies, devices, compositions, etc.), the terms (including a reference to a “means”) used to describe such elements are intended to correspond, unless otherwise indicated, to any element which performs the specified function of the described element (i.e., that is functionally equivalent), even though not structurally equivalent to the disclosed structure which performs the function in the herein illustrated exemplary embodiment or embodiments. In addition, while a particular feature may have been described above with respect to only one or more of several illustrated embodiments, such feature may be combined with one or more other features of the other embodiments, as may be desired and advantageous for any given or particular application.