BOLT INTERFACE COATING AND THREAD TRANSITION GEOMETRY FOR SLEEVED FASTENERS USED IN COMPOSITE APPLICATIONS

Abstract

A bolt for an interference fastener and a fastener system is provided. The bolt has a body extending axially between a first end and a second end. The body has a threaded area extending axially inward from the second end and a head configured on the first end. A cylindrical expansion area extends axially between the head and the transition area. The transition area is disposed axially between the cylindrical expansion area and the threaded area.

Claims

1. A bolt for an interference fastener, the bolt comprising: a body extending axially along a longitudinal axis A between a first end and a second end, the body having a threaded area extending axially inward from the second end and a head configured on the first end; a cylindrical expansion area extending axially between the head and the threaded area; and a transition area disposed axially between the cylindrical expansion area and the threaded area; wherein the transition area is tapered at a transition angle and the transition angle being defined as an angle between the threaded area and the cylindrical expansion area.

2. The bolt of claim 1, wherein the transition angle is greater than 20 degrees.

3. The bolt of claim 1, wherein the transition angle is between 25 degrees and 60 degrees.

4. The bolt of claim 1, wherein at the transition area includes a linear portion and a convex radiused portion, the linear portion being tapered at an angle and the convex radiused portion having a radius R1.

5. The bolt of claim 4, wherein a ratio of a first axial length of the convex radiused portion to a second axial length of the linear portion is between 0.5 and 1.5

6. The bolt of claim 1, wherein the wherein at the transition area includes a single continuous radiused portion.

7. The bolt of claim 1, wherein the transition area is defined by a logarithmic profile according to the equation Y(x)=(A.sub.1/L.sub.90) ln [1/(1(x/L.sub.90).sup.2)].

8. The bolt of claim 1, wherein the transition area includes a first transition area and a second transition area, the first transition area extending a first axial length between the cylindrical expansion area and the second transition area, and the second transition area extending a second axial length between the first transition area and the threaded area.

9. The bolt of claim 8, wherein the first transition area is defined by an arc having a first radius rotated about the longitudinal axis A, the second transition area is defined by an arc having a second radius rotated about the longitudinal axis A, and the first radius is greater in magnitude than the second radius.

10. The bolt of claim 8, wherein the ratio of the first axial length to the second axial length is between 1.0 and 4.0.

11. The bolt of claim 1, wherein the transition area includes a first transition area, a second transition area, and a third transition area; the first transition area is defined by a first line rotated about the longitudinal axis A, the first line extending from the cylindrical expansion area towards the threaded area at a first transition angle ; the second transition area is defined by an arc rotated about the longitudinal axis A, the arc having a radius R1 and extending from the first transition area towards the threaded area; and the third transition area defined by a second line rotated about the longitudinal axis A, the second line extending from the second transition area to the threaded area at a second transition angle ; and wherein the transition angle is the total of the first transition angle and the second transition angle .

12. The bolt of claim 8, wherein the first transition area is defined by an arc rotated about the longitudinal axis A and the second transition area is defined by a line rotated about the longitudinal axis A.

13. The bolt of claim 8, wherein the first transition area is defined by a line rotated about the longitudinal axis A and the second transition area is defined by an arc rotated about the longitudinal axis A.

14. The bolt of claim 12, further comprising a third transition surface between the second transition surface and the threaded area; wherein the third transition surface is defined by a line rotated about the longitudinal axis A.

15. The bolt of claim 12, further comprising a third transition surface between the second transition surface and the threaded area; wherein the third transition surface is defined by an arc rotated about the longitudinal axis A.

16. An interference fastener system comprising: an expandable sleeve including a hollow elongate stem extending axially between an insertion end and a head portion, the elongate stem having an inside surface and an outside surface, the expandable sleeve being configured to be installed in a bore of a substrate; and a bolt, the bolt including a body extending axially between a first end and a second end, the body having a threaded area extending axially inward from the second end, a head portion arranged on the first end, a cylindrical expansion area extending axially between the head portion and the threaded area, and a transition area disposed axially between the cylindrical expansion area and the threaded area, the bolt being configured to be installed in a position abutting the inside surface of the expandable sleeve with a nut, wherein when the nut is tightened, the sleeve expands uniformly in the bore of the substrate.

17. The interference fastener system of claim 16, wherein the transition area is tapered at a transition angle , the transition angle being defined as an angle between the threaded area and the cylindrical expansion area.

18. The interference fastener system of claim 16, wherein the transition angle is greater than 20 degrees.

19. The interference fastener system of claim 16, wherein the transition angle is between 25 degrees and 60 degrees.

20. The interference fastener system of claim 16, wherein the bolt is coated with a lubricant.

21. The interference fastener system of claim 16, wherein the bolt has a first coating disposed on the body, and a second coating disposed on the first coating.

22. The interference fastener system of claim 21, wherein the first coating is a galvanic corrosion resistant coating and the second coating is a dry film lubricant.

23. The interference fastener system of claim 16, wherein the bolt is coated with a sealant before it contacts the inside surface of the expandable sleeve.

24. A bolt for an interference fastener, the bolt comprising: a body extending axially along a longitudinal axis A between a first end and a second end, the body having a threaded area extending axially inward from the second end and a head configured on the first end; a cylindrical expansion area extending axially between the head and the threaded area; and a transition area including a first transition area, a second transition area, and a third transition area disposed axially between the cylindrical expansion area and the threaded area, a tangent reference line of the first transition area intersecting the second transition area defines a first angle relative to the cylindrical expansion area, a tangent reference line of the third transition surface intersecting the threaded area defines a second angle relative to the tangent reference line of the first transition area; wherein a transition angle is the total of the first angle and the second angle .

25. The bolt for an interference fastener of claim 24, wherein at least one of the first transition surface, the second transition surface, and the third transition surface is defined by a line rotated about the longitudinal axis A.

26. The bolt for an interference fastener of claim 24, wherein at least one of the first transition surface, the second transition surface, and the third transition surface is defined by an arc having a radius R1 rotated about the longitudinal axis A.

27. A bolt for an interference fastener, the bolt comprising: a metallic body extending axially along a longitudinal axis A between a first end and a second end, the body having a threaded area extending axially inward from the second end and a head configured on the first end; a cylindrical expansion area extending axially between the head and the threaded area, the cylindrical expansion area having a first outside diameter that is greater than or equal to a second outside diameter of the threaded area; and a transition area disposed axially between the cylindrical expansion area and the threaded area; wherein the transition area comprises at least one of: (a) at least one convex radiused portion; (b) is defined by a logarithmic profile according to the equation Y(x)=(A.sub.1/L.sub.90) ln [1/(1(x/L.sub.90).sup.2)]; and (c) a shape having more than one profile.

28. An interference fastener system comprising: an expandable sleeve including a hollow elongate stem extending axially between an insertion end and a head portion, the elongate stem having an inside surface and an outside surface, the expandable sleeve being configured to be installed in a bore of a substrate, the stem being metallic; and the bolt according to claim 27.

29. The bolt according to claim 27, further comprising a coating disposed on the transition area.

30. A bolt for an interference fastener, the bolt comprising: a body extending axially along a longitudinal axis A between a first end and a second end, the body having a threaded area extending axially inward from the second end and a head configured on the first end; a cylindrical expansion area extending axially between the head and the threaded area; and a transition area including a first transition area having a first profile, a second transition area having a second profile, and a third transition area having a third profile, the first transition area, the second transition area and the third transition area each being located axially between the cylindrical expansion area and the threaded area; wherein the first profile, the second profile and the third profile having different configurations from one another.

31. The bolt according to claim 1, further comprising a coating disposed on the transition area.

Description

DESCRIPTION OF THE DRAWINGS

[0027] The drawings show embodiments of the disclosed subject matter for the purpose of illustrating the invention. However, it should be understood that the present application is not limited to the precise arrangements and instrumentalities shown in the drawings, wherein:

[0028] FIG. 1 is a perspective view of a bolt according to the present invention;

[0029] FIG. 2A is a partial cross sectional view of one embodiment of the transition area of detail A as shown in FIG. 1;

[0030] FIG. 2B is an alternate embodiment of the transition area depicted in FIG. 2A;

[0031] FIG. 3 is a partial cross sectional view of an alternative embodiment of the transition area of detail A as shown in FIG. 1;

[0032] FIG. 4 is a partial cross sectional view of another alternative embodiment of the transition area of detail A as shown in FIG. 1;

[0033] FIG. 5 is a partial cross sectional view of yet another alternative embodiment of the transition area of detail A as shown in FIG. 1;

[0034] FIG. 6 is a partial cross sectional view of another alternative embodiment of the transition area of detail A as shown in FIG. 1;

[0035] FIG. 7 is a cross sectional view of an expandable sleeve according to the present invention;

[0036] FIG. 8 is an isometric view of an axial cross sectional view of a bolt of FIG. 1 and the sleeve of FIG. 7;

[0037] FIG. 9 is a partial axial cross sectional view of a bolt and sleeve of FIG. 7 installed in a substrate;

[0038] FIG. 10A is a perspective view of a bolt according to FIG. 1 including a first and a second coating; and

[0039] FIG. 10B is a perspective view of a bolt according to FIG. 1 including an alternative arrangement of a first and a second coating.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0040] As shown in FIG. 1, a bolt 80 extends from a first end 80A to a second end 80B. The bolt 80 includes a threaded area 82 (e.g., male threads) that extends axially inward from the second end 80B and terminates between the first end 80A and the second end 80B at a point P2. The bolt 80 includes a head 85 on the first end 80A of the bolt 80. The bolt 80 has a cylindrical expansion area 84 extending from the head 85 and terminating at a point P1 at the transition area 180T. Alternative bolts with different head geometries and various threaded ends (including but not limited to tapered heads, threaded ends with pull type ends adjacent to the threaded ends, etc.) do not depart significantly from the invention disclosed herein.

[0041] The transition area of the bolt 80 can be configured in a variety of stress relieving geometries. As shown in FIG. 2A, a transition area 181T of bolt 80 is disposed between points P1 and P2 between the threaded area 82 and the cylindrical expansion area 84. A linear transition area T extends between the transition area 181T and the threaded area 82. The transition angle is defined as the angle between the threaded area 82 and the cylindrical expansion area 84 as shown in FIG. 2A. This transition angle is measured from a reference line, tangent to the transition area 181T, at the intersection of the transition area 181T and the threaded area 82. The transition area 181T includes a convex radiused portion with a radius R1 from points P1 to P3 and a linear transition area T from points P3 to P2. The depicted tangent reference line is colinear with the linear transition area T. As a result, the transition angle is the angle between the linear transition area T and the cylindrical expansion area 84. In some embodiments, the ratio of the axial length of the radiused portion 181T to axial length of the linear transition area T is between 0.5 and 1.5. FIG. 2B depicts an alternate embodiment of the bolt 80, in which the linear transition area T is adjacent to the cylindrical expansion area 84 and the radiused transition surface 181T is adjacent to the threaded area 82.

[0042] Referring to FIG. 3, a transition area 182T of bolt 80 extends from a point P1 at the cylindrical expansion area 84 to a point P2 at the threaded area 82. The transition area 182T is defined by a continuous radiused portion having a radius R1 from points P1 to P2. The depicted reference line that defines the transition angle is tangent to the transition area 182T at point P2.

[0043] Referring to FIG. 4, a transition area 183T of bolt 80 is disposed between a first point P1 at the cylindrical expansion area 84 and a second point P2 at the threaded area 82. In this embodiment, the transition area 183T has logarithmic profile. A transition length L is defined as an axial distance, measured parallel to the A axis of the bolt 80, between the threaded area 82 and the cylindrical expansion area 84. A length L.sub.90 is defined as an axial distance at which the transition angle would be equal to 90 degrees. The transition angle is defined as the angle measured from a tangent reference line that intersects P2 at a distance L as shown in FIG. 4. The depicted surface of the transition area 183T is defined according to the equation:

[00002]$\begin{array}{cc}y\left(x\right)=\frac{A_1}{L_{9.Math.0}}.Math.\ln \left[\frac{1}{1-{\left(\frac{x}{L_{9.Math.0}}\right)}^2}\right]& \left(1\right)\end{array}$

Where y is the ordinate, being perpendicular to the A axis of the bolt 80 directed radially inward from point P1. The values of L.sub.90 and A.sub.1 can be determined for any bolt geometry by measuring a first diameter D1, at point P1 of the cylindrical expansion area 84, and the second diameter D2, measured at point P2 between the transition area 181T-188T and the threaded area 82, as depicted in FIG. 1. Once D1 and D2 are determined, the following equations are used to calculate A.sub.1 and L.sub.90:

[00003]$\begin{array}{cc}Y\left(L^{}\right)=\frac{D.Math.1-D.Math.2}{2}& \left(2\right)\\ {\frac{d.Math.y\left(x\right)}{d.Math.x}.Math.}_{x=L^{}}=& \left(3\right)\end{array}$

In the depicted embodiment, P4 is where a tangent reference line to the surface of the transition area 183T would be a vertical line.

[0044] Referring to FIG. 5, a bolt 80 has a first transition area 184T and a second transition area 185T. The first transition area 184T extends between the cylindrical expansion area 84 at point P1 and the second transition area 185T at point P3. The second transition area 185T extends between the first transition area 184T at point P3 and the threaded area 82 at point P2. The first transition area 184T is defined by a radius R1 having a first axial length L1. The second transition area 185T is defined by a radius R2 having a second axial length L2. In one embodiment, the second radius R2 is smaller than the first radius R1. In one embodiment, the ratio of the first axial length L1 to the second axial length L2 is between 1.0 and 4.0. The transition area 184T ensures that there are no abrupt changes in the angle of the surface of the bolt. A first transition angle is defined between a reference line tangent to the second transition area 184T at point P3. A second transition angle is defined between the reference line tangent to the first transition area 184T at point P3 and the cylindrical expansion area 84. In the depicted embodiment, the cylindrical expansion area 84 is tangent to the first transition area 184T at point P1. The total transition angle =+. In some embodiments, the angle varies over all the transition geometries while the angle varies between 20 and 60, and is preferably between 30 and 35.

[0045] Referring to FIG. 6, a bolt 80 has a first transition area 186T, a second transition area 187T and a linear transition area T. The first transition area 186T extends from the cylindrical expansion area 84 from point P1 to point P3. In the depicted embodiment, the first transition area 186T defined by a line rotated about the longitudinal axis A at a first transition angle relative to the cylindrical expansion area 84. The second transition area 187T is defined by an arc having a radius R1 rotated about the longitudinal axis from point P3 to point P4. The linear transition area T extends from point P2 at the threaded area 82 to point P4. The linear transition area T is defined by a line rotated about the longitudinal axis A at a second transition angle relative to the first transition area 186T. The total transition angle =+. The first transition area 186T has an axial length, measured parallel to the longitudinal axis A, of L1. The second transition area 187T has an axial length L2 and the linear transition area T has an axial length L3. In some embodiments, is between 0 degrees and 10 degrees and preferably between 2 degrees and 5 degrees.

[0046] As shown in FIG. 7, an expandable sleeve 410 for an interference fastener includes a hollow elongate stem 412 extending axially between an insertion end 410A and a head portion 410B. The head portion 410B includes a flange 412F that has a thickness T10. The elongate stem 412 has an inside surface 412A, an outside surface 412B and an overall axial length L. A portion of the stem 412 has a cylindrical shape along an axial length L5 which is about 90 to 95 percent of the overall axial length L. The stem 412 includes a radially outward taper 412R (e.g., truncated conical shape) extending axially toward the head portion 410B. The taper 412R has an axial length L4, which is about 5 to 10 percent of the overall axial length L of the stem. The taper 412R forms an angle 20 relative to a line R20 that is parallel to a longitudinal axis A.

[0047] As shown in FIGS. 8-9, the present invention includes a method for assembling the interference fastener system 99 in a substrate 50. The interference fastener system includes the sleeve 410, bolt 80 and a nut 90, as shown in FIG. 9. In one embodiment, an initial step of the assembly involves sliding the sleeve 410 into a bore 52 of the substrate 50 without any lubrication thereon and without substantial frictional resistance. The insertion end 410A of the sleeve 410 is slid into the entry end 52A of the bore 52 until the flange 410F abuts the substrate 50 proximate the entry end 52A of the bore 52.

[0048] Referring to FIGS. 8 and 9, the bolt 80 is positioned for entry into the sleeve 410 and is slid into the sleeve 410 until the threaded area 82 begins to protrude out of the second end 52B of the bore 52. As shown in FIG. 9, a nut 90 that has female threads 92 is threaded onto the threaded area 82 of the bolt 80. The nut 90 is torqued onto the bolt 80 to further the expansion area 84 of the bolt 80 into the sleeve 410 and to radially expand the stem 412 into a cylindrical shape indicated by element number 410 in FIG. 9. In some embodiments, the bolt 80 is pushed or pulled through the sleeve 410, expanding the sleeve 410. Then the nut 90 is tightened to fix the bolt 80 in place. In some embodiments, the nut is swaged over the threaded area of the bolt. In some embodiments, the bolt 80 is pushed all the way into the sleeve 410 and bore 52 before torqueing the nut 90 on the bolt 80. The expansion of the sleeve 410 against the interior surface 54 of the bore 52 of the substrate 50 provides the electrical communication through the sleeve 410 to the substrate 50.

[0049] The taper 412R has utility in minimizing stresses applied to a substrate 50 when the sleeve 410 is radially expanded in the bore 52 against the interior surface 54. Thus, sleeve 410 having the taper 412R allows a cylindrical shaped stem 412 to be employed and installed in the bore 52 of the substrate 50 without lubrication and without damaging the interior surface 54 upon radial expansion of the sleeve 410. This also prevents failure of the sleeve 410 during insertion in the bore 52.

[0050] The stem 412 of the sleeve 410 is configured for uniformly distributing pressures when the sleeve 410 is expanded in a bore 52 of a substrate 50. The stem 412 also minimizes the stress in the sleeve 410 to prevent sleeve failure during insertion. The stem 412 having a radially outward conical taper 412R extending axially toward the head portion 410B is an example of a stress minimizing feature.

[0051] The sleeve 410 is configured for insertion, insertion end 410A first, into a hole or bore 52 in a substrate 50 (e.g., a substrate in an aircraft such as a panel made of a composite material), as shown in FIG. 9. The sleeve 410 is radially expanded in the bore 52 against an interior surface 54 that defines the bore 52. The tightening of the nut 90 on the bolt 80 radially expands the sleeve 410. In alternative embodiments, the sleeve 410 expands when the bolt 80 is pushed into the sleeve 410, for example a force is applied to the bolt to draw the bolt into the sleeve thereby expanding the sleeve in an interference fit in the bore.

[0052] As shown in FIG. 8, the head portion 410B of the sleeve 410 includes a flange 410F extending radially outward from the stem 412. In one embodiment, the head portion 410B is configured in a flat shape, generally perpendicular to the stem 412. While the head portion is shown and described as being a flange 410F and/or a flat shape, the present invention is not limited in this regard, as other configurations may be employed, including but not limited to a sleeve having a head portion 410B that has conical tapered shape or other shape suitable for use in any shape of countersunk hole in a substrate 50.

[0053] In one embodiment, the sleeve 410 is manufactured from an electrically conductive material, such as a stainless steel, austenitic stainless steel, A286 CRES and AMS 5525. Employing an electrically conductive material for the sleeve 410 has utility in providing electrical communication through the sleeve 410 to the substrate that the sleeve is inserted in during instances of lightning surge flow through aircraft structure, thereby mitigating electrical arcing and protecting hardware. This also allows for the static electricity to dissipate through the sleeve 410 to the substrate without the need for a ground strap.

[0054] In some embodiments, the sleeve 410 can be coated on all exposed surfaces with a lubricant 102, such as for example, cetyl alcohol or with a dry film lubricant such as graphite, molybdenum disulfide or PTFE. In some embodiments, the bolt 80 is coated with a galvanic corrosion resistant coating 104 such as an aluminum pigmented coating.

[0055] The transition areas 180T-188T, T, T, T and all or part of the cylindrical expansion region 84 are preferably coated with a solid dry film lubricant 102.

[0056] In some embodiments, the entire bolt 80 is coated with a second lubricant 106 such as cetyl alcohol after an aluminum pigmented coating and a dry film lubricant 102 are applied.

[0057] In some embodiments, the outside of the sleeve 410 is coated with sealant before being inserted into the bore 52.

[0058] Referring to FIG. 10A, the bolt 80 is coated with a galvanic corrosion resistant coating 104. The galvanic corrosion resistant coating 104 is then coated with a solid lubricant 102 coating thus allowing for elimination of the need for a solid lubricant coating on the inside of the sleeve 410. The galvanic corrosion resistant coating 104 is optional, and may be used depending on the particular application.

[0059] Referring to FIG. 10B, the axial length of the cylindrical area 82 is defined as L and a solid lubricant 102 is disposed on the cylindrical area 84 a distance x. In the depicted embodiment x=L. In some embodiments the ratio of x to L is between 0.1 and 1.0. In detail B of FIG. 10B, the solid lubricant 102 is also disposed on the transition area 188T a distance Y. The distance Y is measured along the surface of the transition area and the total length of the surface of the transition area 188T is L. In some embodiments, the ratio of the distance Y to the total length of the transition area 188T of L is between 0.25 and 1.00. The lengths x and Y of the coating 102 can be adjusted depending on the application. Both lengths are measured from point P1 on the transition area 188T.

[0060] In alternate embodiments, a sealant (not depicted) is substituted in place of one or both of the coatings 102, 104, 102, 104 as depicted in FIGS. 10A and 10B.

[0061] Bolts having a coating on top of an aluminum pigment coating that reduces axial (frictional) installation forces on the sleeve during installation of the bolt reduces the likelihood that the sleeve will tear and eliminates the need for any lubrication or coating on the sleeve internal diameter. Such bolts having thread transition geometries having stress reduction features unexpectedly ensure uniform expansion of the sleeve and reduce the risk of structural damage to the substrate.

[0062] Although the present invention has been disclosed and described with reference to certain embodiments thereof, it should be noted that other variations and modifications may be made, and it is intended that the following claims cover the variations and modifications within the true scope of the invention.