MUSHROOMING EXPANDABLE FASTENER INSTALLATION TOOL AND METHODS

Abstract

Methods, systems and tools for securing to a panel an expandable fastener having a threaded component and a mushrooming component, the tool including a sleeve having a cylindrical body with a hollow inside portion and an internal spline configured to match a splined shoulder of the mushrooming component, a drive shaft having a driving portion configured to engage and rotate the threaded component, the driving portion positioned within the hollow portion of the sleeve, and a driven portion configured to be driven by an arbor, the arbor having a first shaft portion configured to engage with the driven portion and drive the drive shaft, and a second shaft portion configured to connect to a drill or nut driver to drive the drive shaft to turn the threaded component relative to the mushrooming component and collapse the mushrooming component.

Claims

1. An installation tool for use with an expandable fastener having a threaded component and a mushrooming component, the tool comprising: a sleeve comprising a body including a hollow portion and an internal spline region configured to match a splined shoulder of the mushrooming component; a drive shaft comprising a driving portion, a driven portion, and a cavity, the driving portion mounted rotatably within the hollow portion and including a terminal end configured to engage and rotate the threaded component, the driven portion configured to be driven and including an external portion external of the sleeve, and the cavity extending into the driving portion from the driven portion; an arbor configured to engage the driven portion drivenly and secure a drill or nut driver; the cavity configured to receive the arbor and the drill or nut driver when the arbor is engaged to the driven portion drivenly and the arbor is secured to the drill or nut driver; and the driving portion solid in diametric cross-section from the cavity to the terminal end of the driving portion, providing structural integrity for the drive shaft from the cavity to the terminal end of the driving portion.

2. The tool of claim 1, wherein the internal spline region includes multiple, separate splined grooves each defining a point, the points separated from each other along a circular arc of less than 90 degrees.

3. The tool of claim 1, wherein the internal spline region includes 12 splined grooves.

4. The tool of claim 1, wherein the driving portion of the drive shaft includes a hex socket configured to engage with and rotate a hex head of the fastener.

5. An installation tool for use with an expandable fastener having a threaded component and a mushrooming component, the tool comprising: a sleeve comprising a body including a hollow portion and an internal spline region configured to match a splined shoulder of the mushrooming component; a drive shaft comprising a driving portion, a driven portion, and a cavity, the driving portion mounted rotatably within the hollow portion and including a terminal end configured to engage and rotate the threaded component, the driven portion configured to be driven, and the cavity extending into the driving portion from the driven portion; and an arbor configured to engage the driven portion drivenly and secure a drill or nut driver to drive the drive shaft to turn the threaded component relative to the mushrooming component and collapse the mushrooming component; the driven portion including an external portion external of the sleeve, the external portion configured to abut a terminal end of the sleeve during installation of the fastener; the cavity configured to receive the arbor and the drill or nut driver when the arbor is engaged to the driven portion drivenly and the arbor is secured to the drill or nut driver; and the driving portion solid in diametric cross-section from the cavity to the terminal end of the driving portion, providing structural integrity for the drive shaft from the cavity to the terminal end of the driving portion.

6. (canceled)

7. The tool of claim 1, wherein the terminal end of the driving portion of the drive shaft is visible when the drive shaft is within the sleeve.

8. (canceled)

9. The tool of claim 1, wherein the terminal end of the driving portion of the drive shaft comprises a hex socket configured to receive a hex head of the fastener, and the driven portion includes a female hex socket configured to receive the arbor.

10. The tool of claim 1, wherein the driving portion includes a magnet inset from the terminal end of the driving portion.

11. (canceled)

12. The tool of claim 1, wherein the arbor includes a cylindrical cavity configured to receive a drill bit.

13. The tool of claim 1, wherein the sleeve has a maximum length and a maximum diameter, the maximum length is greater than twice the maximum diameter.

14. The tool of claim 5, further comprising the spline region configured to match a shoulder of a fastener having a ⅝ inch 12-point splined holding surface and where the sleeve has a length no less than 1⅝ inches and an external diameter no greater than ⅞ inch.

15. A method of installing an expandable fastener utilizing the tool of claim 14, the tool holding a shoulder of the fastener while turning a head of the fastener to collapse a mushrooming component of the fastener.

16. A system to install a mushrooming expandable fastener utilizing the tool of claim 1 and further comprising an expandable fastener having a 12-point externally splined shoulder, the splined shoulder complementary to the splined region.

17. An installation tool for use with an expandable fastener having a threaded component and a mushrooming component, the tool comprising: a sleeve comprising a body including a hollow inside diameter portion and a socket configured to match a shoulder of the mushrooming component, portions of the socket having an internal diameter greater than an internal diameter of the hollow inside diameter portion; a drive shaft comprising a driving portion, a driven portion, and a cavity, the driving portion mounted rotatably within the hollow inside diameter portion of the sleeve and including a socket configured to engage and rotate a head of the threaded component, the driven portion configured to be driven, and the cavity extending into the driving portion from the driven portion, the driving portion having a maximum outer diameter and the driven portion having a maximum outer diameter, the maximum outer diameter of the driven portion being greater than the maximum outer diameter of the driving portion; an arbor configured to engage the driven portion drivenly and secure a drill or nut driver; the cavity configured to receive the arbor and the drill or nut driver when the arbor is engaged to the driven portion drivenly and the arbor is secured to the drill or nut driver; and the driving portion solid in diametric cross-section from the cavity to the socket of the driving portion, providing structural integrity for the drive shaft from the cavity to the socket of the driving portion.

18. The tool of claim 17, wherein the driven portion defines a shaft elbow which abuts against a terminal end of the sleeve when the drive shaft is inserted into the sleeve and while the sleeve is held into position during installation of the fastener.

19. The tool of claim 17, wherein the socket of the driving portion is a 5/16 inch hex-head socket and configured to rotate a 5/16 inch head of a mushrooming expandable fastener, and the socket of the sleeve is a 12-point internal socket configured to receive a ⅝ inch 12-point shoulder of the fastener.

20. (canceled)

21. The tool of claim 12, wherein the cylindrical cavity of the arbor is defined in part by an arbor cylinder having an external diameter, portions of the first hex shaft portion extending radially beyond the external diameter of the arbor cylinder.

22. The tool of claim 17, wherein the socket of the drive shaft is defined in part by a wall of the drive shaft, the wall having an internal portion and an external cylindrical portion, the external cylindrical portion having a diameter less than a smallest hollow inside diameter of the sleeve.

23. The tool of claim 17, wherein a terminal end of the drive shaft extends at least partially into the socket of the sleeve.

24. The tool of claim 1, wherein an outermost diameter of the drive shaft and an outermost diameter of the sleeve are equal.

25. An installation tool for use with an expandable fastener having a threaded component and a mushrooming component, the tool comprising: a sleeve having a cylindrical body with a hollow inside diameter portion and an internal socket region configured to match a shoulder of the mushrooming component; a drive shaft comprising a driving portion, a driven portion, and a cavity, the driving portion mounted rotatably within the hollow inside diameter of the sleeve and including a terminal end configured to engage and rotate the threaded component, an entirety of the terminal end of the driving portion of the drive shaft visible, the driven portion configured to be driven, and the cavity extending into the driving portion from the driven portion; an arbor configured to engage the driven portion drivenly and secure a drill or nut driver; the cavity configured to receive the arbor and the drill or nut driver when the arbor is engaged to the driven portion drivenly and the arbor is secured to the drill or nut driver; the driving portion solid in diametric cross-section from the cavity to the terminal end of the driving portion, providing structural integrity for the drive shaft from the cavity to the terminal end of the driving portion; and a handle having a prong positioned within a handle port of the sleeve and configured to inhibit removal of the drive shaft from the sleeve.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Some features of the invention are represented by the accompanied drawings. These drawings capture the major defining features of the invention but are not intended to encompass every variation.

[0016] FIG. 1 is a perspective view of a prior art fastener for use with the present invention and with portions shown in cut-away.

[0017] FIG. 2 is a perspective view of the prior art fastener of FIG. 1.

[0018] FIG. 3 is a side view of the fastener of FIG. 1 in a representative installation mode.

[0019] FIG. 4 is a partial side view of the fastener of FIG. 1 in a representative installation mode with portions shown in cut-away.

[0020] FIG. 5 is a side view of a prior art component for use in conjunction with the present invention.

[0021] FIG. 6 is a perspective view of the prior art component of FIG. 5.

[0022] FIG. 7 is a perspective view of a tool in accordance with one aspect of the present invention and including an optional handle component.

[0023] FIG. 8 is an exploded view of the tool of FIG. 7 and including an optional drill bit component.

[0024] FIG. 9 is a perspective view of a component in accordance with one aspect of the tool of FIG. 7.

[0025] FIG. 10 is a section view taken along line 10-10 of FIG. 11.

[0026] FIG. 11 is an end view of the component of FIG. 9.

[0027] FIG. 12 is a perspective view of a component in accordance with one aspect of the tool of FIG. 7.

[0028] FIG. 13 is a section view taken along line 13-13 of FIG. 14.

[0029] FIG. 14 is an end view of the component of FIG. 12.

[0030] FIG. 15 is an end view of the component of FIG. 12.

[0031] FIG. 16 is a perspective view of a component in accordance with one aspect of the tool of FIG. 7.

[0032] FIG. 17 is a side view of the component of FIG. 16.

[0033] FIG. 18 is a section view taken along a longitudinal axis of the tool of FIG. 7.

DETAILED DESCRIPTION OF THE INVENTION

[0034] Referring to FIGS. 7-18, aspects of the tools, systems and methods of installing a fab-lock fastener 20 in accordance with the present invention are presented. FIG. 7 is a perspective view of tool 30 which in one aspect is made of metal such as steel. Tool 30 may be made of other materials. Tool 30 includes a tool sleeve 40, drive shaft 50 and arbor 70. In further aspects tool 30 may include a handle 80 and a drill bit 90. Tool 30 is used to secure fasteners of the FAB-LOCK® fastener variety to panels in order to secure panels together or secure components to the panels. Tool 30 may be used to secure fasteners 20 as shown in FIGS. 1-3, for instance. Tool 30 in one aspect is used to secure fastener 20 to a panel 18 (FIG. 3). Sleeve 40 is placed upon and holds shoulder 27 of the faster 20 while drive shaft 50 is placed upon and rotates the head 23 of the fastener 20, thus collapsing sleeves 26 of the fastener 20 to secure the fastener 20 to panel 18 as shown in FIG. 3. The arbor 70 inserts into a drill 10 (or other spinning device such as a nut driver). Arbor 70 is connected to drive shaft 50 to spin the head 23. A handle 80 connected to sleeve 40 is grasped by a worker to hold sleeve 40 in relatively fixed position so that sleeve 40 does not or only minimally rotates in order to hold shoulder 27 in position while drive shaft turns head 23. As head 23 is turned while shoulder 27 is maintained stationary, the sleeves 26 of fastener 20 mushroom to secure the fastener 20 to the panel 18. In some cases the fastener 20 secures a panel 18 to a component or other panel 17, or secures a component 17 to a panel 18, for instance.

[0035] FIG. 8 shows tool 30 in exploded view and depicts how arbor 70 inserts into drive shaft 50 and how drive shaft 50 inserts into sleeve 40. Handle 80 secures into handle ports 48 of sleeve 40, securing drive shaft 50 within sleeve 40.

[0036] FIG. 9, FIG. 10 and FIG. 11 depict sleeve 40 having a cylindrical body 42 with a hollow inside diameter portion 43. In one aspect socket 46 includes an internal spline region 44 which is located at an outward end of sleeve 40. Spline region 44 is configured to match a splined shoulder 27 of fastener 20. In one aspect splined region 44 includes splines 45 and/or spline grooves 45a, 45a. Splines 45 are formed on the inner side of body 42. In one aspect the internal spline region 44 includes multiple, separate splined grooves 45a, each groove defining a point 45b, the points 45a separated from each other along a circular arc of less than 90 degrees. In one aspect the points 45a are separated from each other along a circular arc of 30 degrees as shown in FIG. 11. In one aspect, four separate spline grooves 45a include points 45b, where the separation between the point 45b of the first spline groove 45a and the point 45b of the fourth spine groove 45a is 90 degrees. In one aspect as shown in FIG. 11, a set of 12 spline points 45b and associated spline grooves 45a are presented. These splines 45a are configured to match with and receive the splined shoulder 27 of fastener 20, which fastener 20 includes corresponding or matching external splines. In one aspect the pattern of socket 46 is a 0.625 12-point spline arrangement, with 0.130 deep spline grooves 45a measured from terminal end of sleeve 40. In one aspect, outer diameter “d” of sleeve 40 measures 0.850 inches and having a sleeve length of 2.85 inches. While a different number of separate splined grooves 45a may be used for internal spline region 44, use of 12 equally spaced splined grooves 45a is important for making sure tool 30 operates with a FAB-LOK type of fastener having a corresponding 12-popint externally splined shoulder 27. In further aspects, the socket 46 of sleeve includes a 12-sided socket without spline grooves 45a, and is instead a 12-sided internal socket configured to receive a 12 sided shoulder 27 of a fastener. The points 45b of a non-splined socket 46 may also be separated from each other along a circular arc of 30 degrees. Spline grooves 45a need not always be included in socket 46 in order to effectively achieve a shoulder-holding capability. In one aspect, the 12-sided internal socket comprises 12 connecting internal wall structures. In other aspect, a different number of sides are used for socket 46 to mate with a shoulder 27 having a corresponding number of sides and structure.

[0037] In one aspect it is important that the length of sleeve 40 be at least two times the measurement of its diameter “d” in order for tool 30 to function best in securing components 17, such as securing fasteners 20 within struts 13 or other components. For instance, a sleeve having such ratio or configuration allows for insertion of the sleeve 40 into an opening 15 of a strut 13 or other component while also having handle 80 positioned sufficiently outside of the opening 15 for operation. This allows a worker to sufficiently hold in place the shoulder 27 of fastener by holding the handle 80, while simultaneously spinning the head 23 positioned within opening 15. Such dimension of the length being at least two times the measurement of the diameter provides the ability to have the sleeve 40 insert within a strut 13 while also being able to hold the sleeve 40 in relative position. This avoids the need to insert a box wrench or use a vice grip or other tool in an attempt to secure the shoulder 27 which is positioned internal the opening 15 of a strut 13 or other component. Were the length of sleeve 40 not at least twice its diameter (or where the handle 80 is not set back at least 1⅝ inches from terminal end of sleeve 40), tool 30 would not be able to be positioned, for instance, in a 1⅝ inch Unistrut so that the terminal end of sleeve 40 fully touches the inside bottom portion of strut 13 while handle 80 maintains clearance from strut 13.

[0038] FIG. 12, FIG. 13, FIG. 14 and FIG. 15 depict drive shaft 50 having a driving portion 52 and a driven portion 56. Driving portion 52 includes a socket 53 which is configured to rotate the threaded component 22 of fastener 20. Particularly, socket 53 engages with head 23 to rotate the threaded shank of fastener 20. In one aspect socket 53 is a 3/16 inch female hex socket to receive a 3/16 inch hex head of fastener 20. The driving portion 52 is positioned with the hollow inside diameter portion 43 of sleeve 40. The driven portion 56 is configured to be driven by arbor 70. The driven portion 56 also includes a socket 57 to receive the arbor 70. In one aspect socket 57 is a ⅜ inch female hex socket to receive a ⅜ inch hex shaft or head of arbor 70. In one aspect, socket 53 includes a hex arrangement with six hex points 53a positioned internally. The hex points 53a may also be part of splined grooves positioned in a hex arrangement and configured to mate with a hex head 23. It may be appreciated that corresponding metric units may be used in addition to or as alternatives to the stated measurements herein.

[0039] In one aspect driven portion 56 includes a shaft elbow 58 which abuts against a terminal end 49 of sleeve 40 when the drive shaft 50 is inserted into the sleeve 40. A maximum diameter of driven portion 56 is greater than a maximum diameter of driving portion 52. The driven portion 52 has a maximum outer diameter which is greater than the inside diameter portion of the sleeve 40. In one aspect, an entirety of a terminal end 54 of the driving portion 52 is visible when the drive shaft 50 is positioned within sleeve 40 (See also FIG. 7). For instance, when viewing the drive shaft 50 at the end where socket 53 is located, an entirety of the terminal end 54 of driving portion 52 will be visible. There are no portions of sleeve 40 which obscure or cover the terminal end 54. In further aspects, an entirety of the hollow inside diameter portion 43 is greater than the outer diameter of the driving portion 52. This allows the driving portion 52 to slide freely to or toward spline region 44.

[0040] In one aspect driving portion 52 includes a solid cross-section area 59. The solid area 59 provides structural integrity for shaft 50, and also presents a shelf 61 for securing a magnet 60 within socket 53. Magnet 60 is inset from terminal end 54 of the driving portion 52. The magnet 60 is positioned, or its position is selectively altered, to impart a magnetic force upon the hex head 23 of the fastener 20. Such magnet 60 allows a user to conveniently insert and hold a fastener 20 within tool 30 while in operation. In one aspect, driving portion 52 has a length extending from shaft elbow 58 to terminal end 54 of 2.750 inches (while sleeve 40 has a total length of 2.85 inches). Other sizes may be used, provided terminal end 54 is positioned at or closely adjacent to internal spline region 44 of sleeve 40. This positioning is important so that the socket 53 may receive head 23 of fastener 20 while spline region 44 simultaneously receives shoulder 27 of fastener 20, particularly where the head 23 and shoulder 27 are arranged in close proximity (or abut each other) as in a FAB-LOK type of fastener 20.

[0041] Drive shaft 50 also includes a neck 62 which provides a clearance for receipt of prongs 82 of handle 80 when prongs 82 are inserted into handle ports 48 of sleeve 40. The prongs 82 lock drive shaft 50 within sleeve 40 so shaft 50 cannot be removed easily. Handle 80 is tong shaped and flexible to allow the ends of handle to spread apart and thus allow retraction (or insertion) of prongs 82 into handle ports 48.

[0042] FIG. 16 and FIG. 17 depict arbor 70 having a first shaft portion 72 and second shaft portion 74. First shaft portion 72 is configured to engage with the driven portion 56 of drive shaft 50 and the second shaft portion 74 is configured to connect to a drill 10 or other turning tool such as a nut driver to drive the drive shaft 50. In one aspect first shaft portion 72 includes a hex-shaped shaft aspect 73 which secures into the corresponding hex shaped socket 57 of drive shaft 50. In one aspect second shaft portion 74 includes a hex shaped aspect 75 to be inserted into a chuck or other component of a drill 10 or other tool. Hex aspect 73 in one case is a ⅝ inch hex. A double aspect 75 may also be included for insertion into a nut driver. The hex aspect 75 may include a 5/16 inch hex or even a larger hex size (⅝ inch or larger) to accommodate more secure insertion into a chuck of a drill or screwdriver tool. Arbor 70 includes a cavity 76 to receive an optional drill bit 90. Cavity 76 may be cylindrical or other configuration. A port is defined within arbor 70 and configured to receive a set-screw to secure a drill bit 90 into cavity 76. Drill bit 90 is handy to have for efficient use of tool 30 when switching between a hole-drilling mode and a fastener install mode. A relief 79 is included to receive a flexible O-ring 79′ upon arbor 70. O-ring 79′ friction-fits within socket 57 of drive shaft. Drive shaft 57 includes a corresponding rim 77 which projects inward from inner wall of socket 57 to provide a slight rim to receive and friction-fit O-ring 79′ to allow selective insertion and retraction of arbor 70 from drive shaft 50.

[0043] FIG. 18 is a section view of tool 30 showing arbor 70 having a drill bit 90 inserted into drive shaft 50 which drive shaft 50 inserted into sleeve 40. Handle 80 is available for convenient holding and relative stabilization of sleeve 40 while the user spins arbor 70 with a drill driver or other tool. When access is desired to utilize the drill bit 90, the arbor is conveniently removed from the drive shaft with a pulling force to overcome the friction-fit caused by the O-ring within the drive shaft socket 57. An alternative detent or detent ball may be utilized instead of an O-ring, where a ball may be positioned in the wall of the drive shaft and retained in position by use of an exterior elastic band to apply pressure to the ball and prevent the ball from escape while applying elastic pressure and friction-fit for the ball press inward and to retain arbor 70 within socket 57.

[0044] Tool 30 is configured to conveniently fit within the opening 15 of a strut 13 in order to easily secure strut 13 to a panel 18. The external diameter of sleeve 40 is no greater than ⅞ inches and allows for convenient insertion into a standard 1⅝ inch strut. Sleeve 40 also has a length no less than 1⅝ inches to that handle 80 may still hold sleeve 40 while a terminal end of sleeve may rest against an inside portion of the strut 13. Such length and width dimension of sleeve 40 and tool 30 allows for ease of insertion of a fastener 20 into strut 13 without having to use a separate box wrench, vice grips or other tool to hold shoulder 27 of the fastener. A user will conveniently utilize the drill bit 90 of the tool 30 and swiftly switch to include the combined drive shaft 50 and sleeve 40 which are connected with handle 80.

[0045] Shaft elbow 58 of drive shaft 50 is positioned upon the drive shaft a critical distance from terminal end 54 and in relation to the length of sleeve 40 so that when shaft 50 is fully inserted into sleeve 40, the socket 53 is positioned to receive head 23 while shoulder 27 is simultaneously engaged by socket 46. In one aspect, shaft elbow 58 is positioned 2.750 inches from end 54 while sleeve 40 has a total length of 2.85 inches. The length of sleeve 40 is at least twice the diameter of sleeve 40 to accommodate having a sufficiently narrow profile and sufficient length to secure fasteners 20 within a 1⅝ inch strut 13. The narrow profile and long length also allow for tool 30 to easily secure fasteners withing other difficult to access locations, such as when fastening conduit pipe clamps or the like. In one aspect neck 62 has an outer diameter of 0.470 inches which provides clearance to receive prongs 82 to secure drive shaft 50 within sleeve 40.

[0046] In a further method aspect, the invention includes utilizing a tool 30 to secure a fastener 20 to a panel. The method includes positioning the socket 46 of sleeve 40 upon the shoulder 27 of fastener 20, simultaneously positioning the socket 53 of drive shaft 50 upon head 23 of the fastener, and turning the head 23 while holding the shoulder 27 in a relatively fixed position. The turning action causes sleeves 26 of the fastener 20 to mushroom and secure the fastener to a panel 18. In aspects, the turning is accomplished using a screwdriver, drill or drill driver, and the holding is accomplished by grasping handle 80 and resisting turning of sleeve 40. A further method includes positioning the sleeve 40 within an opening of a strut 13 and utilizing the method securing steps noted herein. In further aspects the invention includes systems where the tool 30 in conjunction with a fastener 20 is used to secure fastener 20 by operation as noted.

[0047] It should be understood, of course, that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims.