A tapered fastener adapted to be installed in an unthreaded, tapered hole in a workpiece formed of a cast material is provided. The tapered fastener can have a head and a shank. The shank can have a tapering outer face with substantially the same tapering angle as the tapered hole in the workpiece. A thread forming screw thread in the tapering outer face forms threads in the unthreaded, tapered hole as the head drives the shank into the workpiece.

TECHNICAL FIELD

This application relates in general to thread fastener members and more specifically to tapered fasteners insertable into a tapered aperture of a cast material.

BACKGROUND

Known metallic fasteners (e.g., inserts, screws, bolts, studs, rivets, anchors, etc.) are adapted to be fitted in generally straight bores. For machined parts, bores are often drilled resulting in a uniform cross-section for the length of the bore. In contrast to bores drilled in machined parts, holes formed in cast parts may not meet tolerance requirements for installation of the fastener without post-processing.

SUMMARY

The casting process enjoys certain advantages vis-a-vis other shaping processes such as forging, welding, stamping, rolling, extruding, etc. For example, a significant advantage of casting over machining is casting is highly adaptable to the requirements of mass production. Large numbers of a given casting can be produced rather quickly. For example, the automotive industry casts a massive number of workpieces including engine blocks, subframes, seat components (e.g., belt anchors, frames, etc.), motor housings, and transmission cases. While as-cast workpieces are generally dimensionally stable from piece to piece, challenges present themselves when cast workpieces include cast holes. While the holes can be dimensionally stable, their dimensions may vary along a depth of the hole resulting in a tapering shape. Further, cast holes can cause the workpiece to stick within the die delaying removal of the workpiece from the die.

This tapering shape of a hole can be machined straight as part of post-processing. If time and cost permits, post-processing can include machining (drilling) the hole to meet tolerance requirements for the subsequently installed fastener.

The fasteners described herein can be inserted into a cast hole without having to post-process the hole prior to insertion of the fastener. The geometry (e.g., size, shape, profile, material, etc.) of the fasteners allows the fasteners to be installed in tapering holes without post-processing (e.g., drilling). The geometry of the fastener can provide a structural attachment (e.g., engine blocks, subframes, seat components such as belt anchors and frames, motor housings, and transmission cases) for a fastener to the workpiece. Removing post-processing steps for a single mass produced cast part in the automotive industry can reduce costs and provide those cost savings to the consumer.

An aspect is directed to a tapered fastener adapted to be installed in an unthreaded, tapered hole in a workpiece formed of a cast material. Exemplary cast materials can include non-ferrous metals (e.g., aluminum, copper, lead, nickel, tin, titanium and zinc, as well as copper alloys like brass and bronze). Of course other materials (e.g., ferrous metals, plastics, etc.) also fall within the scope of this disclosure.

An aspect of the disclosure is directed to a fastener adapted to be installed in an unthreaded, tapered hole in a workpiece formed of a cast material. The fastener comprises a head having a driving arrangement and a shank comprising a tapering outer face with substantially the same tapering angle as the tapered hole in the workpiece, and a thread forming screw thread disposed in the tapering outer face and configured to form threads in the unthreaded, tapered hole as the head drives the shank into the workpiece.

A variation of the aspect above is, wherein the head has an aperture, the aperture being sized and shaped to receive a threaded fastener.

A variation of the aspect above is, wherein the shank has a generally tubular shape.

A variation of the aspect above is, wherein the shank comprises a screw thread formed inside the tubular shank and configured to receive a threaded fastener.

A variation of the aspect above is, wherein the fastener is configured as an insert.

A variation of the aspect above is, wherein the fastener is configured as a screw.

A variation of the aspect above is, wherein the fastener is configured as a double ended stud.

A variation of the aspect above is, wherein the fastener further comprises a stud sized and shaped to receive a fastener.

A variation of the aspect above is, wherein the stud is threaded.

A variation of the aspect above is, wherein the stud is plain.

A variation of the aspect above is, wherein the driving arrangement is a rachet.

A variation of the aspect above is, wherein the tapered hole in the workpiece has a tapering angle greater than 1.5 degrees.

A variation of the aspect above is, wherein a difference between the tapering angle of the workpiece and the tapering angle of the shank is no greater than 1.5 degrees.

A variation of the aspect above is, wherein the tapering angle of the shank is4degrees.

A variation of the aspect above is, wherein the tapering angle of the workpiece is4degrees.

A variation of the aspect above is, wherein the thread forming screw thread has a pitch and a depth which are substantially the same.

A variation of the aspect above is, wherein the thread forming screw thread is trilobular.

A variation of the aspect above is, wherein the tapering outer face has a maximum outer diameter greater than that of a minimum inner diameter of the tapered hole in the workpiece.

A variation of the aspect above is, wherein the fastener is forged steel.

A variation of the aspect above is, wherein the cast material is aluminum.

A variation of the aspect above is, wherein the fastener provides a structural attachment for a threaded fastener to the workpiece.

An aspect of the disclosure is directed to a threaded insert adapted to be installed in an unthreaded, tapered hole in a workpiece formed of a cast material. The insert comprises a head having a driving arrangement and an aperture, the aperture being sized and shaped to receive a threaded fastener and a generally tubular shank comprising a tapering outer face with substantially the same tapering angle as the tapered hole in the workpiece, a thread forming screw thread disposed in the tapering outer face and configured to form threads in the unthreaded, tapered hole as the head drives the tubular shank into the workpiece, and a screw thread formed inside the tubular shank and configured to receive the threaded fastener.

A variation of the aspect above is, wherein the driving arrangement is a rachet.

i A variation of the aspect above is, wherein the tapered hole in the workpiece has a tapering angle greater than1.5degrees.

A variation of the aspect above is, wherein a difference between the tapering angle of the Nvorkpiece and the tapering angle of the shank is no greater than 1.5 degrees.

A variation of the aspect above is, wherein the tapering angle of the shank is 4 degrees.

A variation of the aspect above is, wherein the tapering angle of the workpiece is 4 degrees.

A variation of the aspect above is, wherein the thread forming screw thread has a pitch and a depth which are substantially the same.

A variation of the aspect above is, wherein the thread forming screw thread is trilobular.

A variation of the aspect above is, wherein the tapering outer face has a maximum outer diameter greater than that of a minimum inner diameter of the tapered hole in the workpiece.

A variation of the aspect above is, wherein the threaded insert is forged steel.

A variation of the aspect above is, wherein the cast material is aluminum.

A variation of the aspect above is, wherein the threaded insert provides a structural attachment for the threaded fastener to the workpiece.

An aspect of the disclosure is directed to a method of installing a tapered fastener in an unthreaded, tapered hole in a workpiece formed of a cast material. The method comprises providing a tapered fastener having a head and shank, the head comprising a driving arrangement, the shank comprising a tapering outer face with substantially the same tapering angle as the tapered hole in the workpiece, the tapering outer face comprising a thread forming screw thread, inserting at least a portion of the shank into the unthreaded, tapered hole, and driving the fastener via the driving arrangement into the unthreaded, tapered hole to form threads in the unthreaded, tapered hole.

A variation of the aspect above further comprises pushing excess material out of the unthreaded, tapered hole by plastic deformation.

A variation of the aspect above further comprises coupling a second fastener to the tapered fastener.

DETAILED DESCRIPTION

Generally described, one or more aspects of the present disclosure relate to a tapered fastener (e.g., inserts, screws, bolts, studs, rivets, anchors, etc.) insertable into a tapered aperture or hole of a cast material. In certain embodiments, the tapered fastener provides a female thread for subsequent insertion of a screw or bolt. In certain embodiments, the disclosure relates to a tapered fastener adapted to be installed in an unthreaded, tapered hole in a workpiece formed of a cast material is provided. The tapered fastener can have a head and a shank (solid, tubular, etc). The shank can have a tapering outer face with substantially the same tapering angle as the tapered hole in the workpiece. A thread forming screw thread in the tapering outer face forms threads in the unthreaded, tapered hole as the head drives the tubular shank into the workpiece. In certain embodiments, a screw thread is formed inside the shank to receive a threaded fastener.

The tapered fasteners disclosed herein are designed to be directly installed in holes of a casting (e.g., non-ferrous castings) without requiring post-processing to machine the hole to remove any taper. Exemplary cast materials can include non-ferrous metals (e.g., aluminum, copper, lead, nickel, tin, titanium and zinc, as well as copper alloys like brass and bronze). Of course other materials (e.g., ferrous metals, plastics, etc.) also fall within the scope of this disclosure.

In certain embodiments, the hole has a taper of 4 degrees. Of course the magnitude of the taper is not limited to 4 degrees and can be above or below 4 degrees. For example, the taper of the hole can be 2 degrees. 2.5 degrees, 3 degrees, 3.5 degrees, 4.5 degrees, 5 degrees, 5.5 degrees, 6 degrees, 6.5 degrees, 7 degrees, etc. including values within and ranges of the listed values. The shank can have a substantially same taper angle as the tapered hole in the workpiece. Of course the tapers need not be substantially the same to fall within the scope of this disclosure. For example, in certain embodiments, the taper of the shank is within 1.5 degrees of the taper of the hole. In other embodiments, the taper of the shank is within 2 degrees of the taper of the hole. In other embodiments, the taper of the shank is within 2.5 degrees of the taper of the hole. In other embodiments, the taper of the shank is within 3 degrees of the taper of the hole. Other magnitudes of the difference between the taper of the shank and the taper of the hole fall within the scope of this disclosure.

In this way, the tapered fastener disclosed herein obviate the need for post-processing the hole in preparing for insert installation in the workpiece; allow holes to be cast with easily achievable tapers (e.g., larger) in contrast to requiring to cast straight or very slight tapered holes (e.g., <1.5 degrees of taper) for mass produced parts. For example, straight or slightly tapered holes can cause the part to stick within the manufacturing die prolonging manufacturing time. By allowing larger tapered holes which are less likely to stick within the manufacturing die, for example, the manufacturing casting process is more efficient without creating a need for post-processing of the larger tapered holes.

The fasteners disclosed herein are easier to align with the hole due to the tapering shapes of the fastener and/or hole. For example, a distal end of the fastener can be simply dropped into the hole and achieve adequate alignment for be driven without the need for a robust alignment process. Such an advantage simplifies the assembly process saving time and cost.

The fasteners disclosed herein can further provide an increased tensile pull-out strength as compared to straight fasteners. For example, the tapering or conical shape of the fastener forms a wedge like action within the hole that results in hoop stresses being created in the workpiece or casting. The hoop stresses multiply the friction at the interface between the casting and the fastener increasing pull-out strength over straight fasteners.

The assembly weight of the fastener acid the workpiece can be less when compared to a workpiece that has non-tapered holes even though the density of the tapered fastener (e.g., steel) can be higher than the as-cast material (e.g., aluminum). This weight savings is partly due to the holes being slightly smaller than non-tapered holes.

FIG.1is a top view of a tapered fastener in the form of an insert20adapted to be installed in an unthreaded, tapered hole22(FIG.3) in a workpiece24. In certain embodiments, the workpiece24is formed of a cast material.FIG.2is a partial cross-section view through the threaded insert20ofFIG.1taken along lines2-2. inFIG.1. In certain embodiments, the threaded insert20includes a taper34.FIG.3is a cross-section view through a workpiece24that was cast with a hole22configured to subsequently receive the threaded insert20ofFIGS.1and2. In the illustrated embodiment, the hole22in the workpiece24has diameter62and a taper60. The threaded insert20disclosed herein are designed to be directly installed in the hole22of the workpiece24(e.g., non-ferrous castings) without requiring post-processing to machine the hole22after casting the workpiece24. For, example, the threaded inserts20disclosed herein can be aligned and driven into the hole22without having to machine the hole to cut away the as-cast taper of the hole22.

In certain embodiments, the hole22has a taper60of about 4 degrees. Of course the magnitude of the taper60is not limited to 4 degrees and can be above or below 4 degrees. For example, the taper 60 of the hole 22 can be 2 degrees, 2.5 degrees, 3 degrees, 3,5 degrees, 4.5 degrees, 5 degrees, 5.5 degrees, 6 degrees, 6.5 degrees, 7 degrees, etc. including values within and ranges of the listed values.

In certain embodiments, the workpiece24comprises a countersink68formed at the top of the hole22. In certain embodiments, the countersink68can insure that the threaded insert20is easy to align with the hole22. In certain embodiments, the countersink68can be deep or shallow relative to the workpiece24. For example, in certain embodiments, the countersink68can insure that the threaded insert20sits flush to the workpiece24. In certain embodiments, the countersink68produces a conical opening for the hole22matching an angle on the threaded insert20(e.g., an tapered head26) so that when the threaded insert20is fully engaged the head26will sit flush or slightly below the surface of the workpiece24. In certain embodiments, a bottom of the hole22comprises a radius66.

In certain embodiments, the threaded insert20includes a head26and a shank32. In the illustrated embodiments, a radius48joins surfaces of the head26and the shank32. The head26can comprise aperture28configured for a fastener200to be inserted therein after the threaded insert20is installed in the workpiece24. In certain embodiments, the threaded insert20is made of a higher tensile strength and harder material than the workpiece24, such as a steel, including stainless or spring steel. Of course other materials for the threaded insert20fall within the scope of this disclosure.

The fastener200can be any type of fastener such as a threaded screw or bolt, etc. Of course the fastener200can be a different type of fastener (e.g., plug, rivet, pin, stud, etc.) that is complementary to the internal channel within the threaded insert20. In exemplary use, the fastener200can provide hold-down capability to engage another item (not shown) to the workpiece24, or can act as an electrical contact post or electrical connection for the workpiece24.

The head26can include a driving arrangement30. The driving arrangement30can be sized and shaped to be engaged by a wrench, ratchet, drill, impact wrench, or other driving tool known to a person having ordinary skill in the art. Air powered or pneumatic tools are also within the scope of this disclosure. In the illustrated embodiment, the driving arrangement30is a hex head.

The shank32can have a generally tubular or hollow shape. For example, in certain embodiments, the shank32includes an internal channel. In certain embodiments, the shank32has a tapering outer face, In certain embodiments, the shank32has substantially the same angle of taper34as the taper60of the hole22in the workpiece24. Of course, the taper34of the shank32and the taper60of the hole22need not be the same. In certain embodiments, the taper34of the shank32is different from the taper60of the hole22. For example, in certain embodiments, the taper34of the shank32is within 1.5 degrees of the taper60of the hole22. In other embodiments, the taper34of the shank32is within 2 degrees of the taper60of the hole22. In other embodiments, the taper34of the shank32is within 2.5 degrees of the taper60of the hole22. In other embodiments, the taper34of the shank32is within 3 degrees of the taper60of the hole22. Other magnitudes of the difference between the taper34of the shank32and the taper60of the hole22fall within the scope of this disclosure.

In certain embodiments, the tapering outer face has a maximum outer diameter46. In certain embodiments, the hole22in the workpiece24has a minimum inner diameter. In certain embodiments, the maximum outer diameter46is greater than that of the minimum inner diameter of the hole22in the workpiece24. In certain embodiment, the taper34can extend for the longitudinal length of the shank32. In certain embodiment, the taper34extends for at least a portion of the longitudinal length of the shank32.

In certain embodiments, a taper36is measured with reference to a centerline38of the threaded insert20. In the illustrated embodiment, the taper36corresponds to half of the magnitude of the taper34.

In certain embodiments, the threaded insert20comprises a thread forming screw thread40(e.g., asymmetrical thread). In certain embodiments, the thread forming screw thread40comprises 3, 5, or 7 lobes. In certain embodiments, the thread forming screw thread40is disposed in the tapering outer face of the shank32. In certain embodiments, the thread forming screw thread40has a pitch and a depth which are substantially the same. In certain embodiments, the thread forming screw thread40has a parabolic shape. In certain embodiments, the thread forming screw thread40is trilobular or pentalobular. In certain embodiments, the thread forming profile can have at least a partial section of the thread40designed as an asymmetrical thread (e.g., three-lobed). For example, a trilobular thread can have a cross-section with three-sides of equal thickness.

In certain embodiments, the thread forming screw thread40forms threads in the unthreaded, tapered hole22of the workpiece as the head26drives the shank32into the workpiece24. For example, in certain embodiments, the thread forming screw thread40roll-forms the threads in the unthreaded, tapered hole22of the workpiece24as the head26drives the shank32into the workpiece24pushing excess material out of the way by plastic deformation.

The formed threads in the hole22are sized and shaped to receive the fastener200. In certain embodiments, the thread forming screw thread40begins a distance44from a bottom surface of the head26. The shank32of the threaded insert20is generally completely received within a thickness64of the workpiece24in a general direction parallel to the thickness64. In certain embodiments, the threaded insert20has a length42.

In certain embodiments, the aperture28in the head26extends through the shank32. For example, in the illustrated embodiment, the aperture28extends for the entire length of the shank32. In the illustrated embodiment, the aperture has a diameter52. In the illustrated embodiment, the diameter52is sized to receive a 14 mm fastener200. Of course the diameter52is not limited to the listed size and can have any other size (e.g., 8 mm, 10 mm, 12 mm, 16 mm, etc.). The aperture28is sized to receive the fastener200.

In certain embodiments, the threaded insert20comprises a countersink54formed at the top of the aperture28in the head26. In certain embodiments, the countersink54can insure that a fastener200(e.g., flat head screw, flat head bolt) sits flush to the head26. In certain embodiments, the countersink68produces a conical opening for the hole22matching the angle of the fastener200so that when the fastener200is fully engaged, the head of the fastener200will sit flush or slightly below the surface of the threaded insert20.

In certain embodiments, the threaded insert20comprises a screw thread50. In certain embodiments, the screw thread50is disposed inside the tubular shank32. In certain embodiments, the screw thread50has a pitch and a depth which are substantially the same. In certain embodiments, the screw thread50is configured to receive the fastener200.

FIG.4is a top view of another embodiment of a threaded insert120adapted to be installed in an unthreaded, tapered hole122in a workpiece124formed of a cast material.FIG.5is a partial cross-section view through the threaded insert122ofFIG.4taken along lines5-5inFIG.4. In certain embodiments, the threaded insert120includes a taper134.FIG.6is a cross-section view through the threaded insert120ofFIG.5taken along lines6-6inFIG.5showing a relief174in a distal portion of the inside of the tubular shank131The relief174can improve packaging for the threaded insert120. In certain embodiments, the relief174can have a minimum inner diameter170and a maximum outer diameter172.

FIG.7is a cross-section view through a workpiece124that was cast with a hole122configured to subsequently receive the threaded insert120ofFIGS.4-6without post-processing. In the illustrated embodiment, the hole122in the workpiece124has diameter162and a taper160. The threaded insert120disclosed herein are designed to be directly installed in the hole122of the workpiece124(e.g., non-ferrous castings) without requiring post-processing after the workpiece124is cast to machine the hole122removing any taper. In certain embodiments, the hole122has a taper160of 4 degrees. Of course the magnitude of the taper160is not limited to 4 degrees and can be above or below4degrees. For example, the taper160of the hole122can be 2 degrees, 2.5 degrees, 3 degrees, 3.5 degrees, 4.5 degrees, 5 degrees, 5.5 degrees, 6 degrees, 6.5 degrees, 7 degrees, etc. including values within and ranges of the listed values.

In certain embodiments, the workpiece124comprises a countersink168formed at the top of the hole122. In certain embodiments, the countersink168can insure that the threaded insert120is easy to align with the hole122. In certain embodiments, the countersink168can be deep or shallow relative to the workpiece124. For example, in certain embodiments, the countersink168can insure that the threaded insert120sits flush to the workpiece124. in certain embodiments, the countersink168produces a conical opening for the hole122matching an angle on the threaded insert120(e.g., an tapered head126) so that when the threaded insert120is fully engaged the head126will sit flush or slightly below the surface of the workpiece124. In certain embodiments, a bottom of the hole122comprises a radius166.

In certain embodiments, the threaded insert120includes a head126and a shank132. In the illustrated embodiments, a radius148joins surfaces of the head126and the shank132. The head126can comprise aperture128configured for a fastener200to be inserted therein after the threaded insert120is installed in the workpiece124. In certain embodiments, the threaded insert120is made of a higher tensile strength and harder material than the workpiece124, such as a steel, including stainless or spring steel. Of course other materials for the threaded insert120fall within the scope of this disclosure.

The fastener200can be any type of tapered fastener such as a screw or bolt, etc. Of course the fastener200can be a different type of fastener (e.g., plug, keyway, etc.) that is complementary to the internal channel within the threaded insert120. In exemplary use, the fastener200can provide hold-down capability to engage another item not shown) to the workpiece124, or can act as an electrical contact post or electrical connection for the workpiece124.

The head126can include a driving arrangement130. The driving arrangement130can be sized and shaped to be engaged by a wrench, ratchet, drill, impact wrench, or other driving tool known to a person having ordinary skill in the art. Air powered or pneumatic tools are also within the scope of this disclosure. In the illustrated embodiment, the driving arrangement130is a hex head.

The shank132. can have a generally tubular or hollow shape. For example, in certain embodiments, the shank132includes an internal channel. In certain embodiments, the shank132has a tapering outer face. In certain embodiments, the shank132has substantially the same angle of taper134as the taper160of the hole122in the workpiece124. Of course, the taper134of the shank132and the taper160of the hole122need not be the same. In certain embodiments, the taper134of the shank132is different from the taper160of the hole122. For example, in certain embodiments, the taper134of the shank132is within1.5degrees of the taper160of the hole122. In other embodiments, the taper134of the shank132is within 2 degrees of the taper160of the hole122. In other embodiments, the taper134of the shank132is within 2.5 degrees of the taper160of the hole122. In other embodiments, the taper134of the shank132is within3degrees of the taper160of the hole122. Other magnitudes of the difference between the taper134of the shank132and the taper160of the hole122fall within the scope of this disclosure.

100961In certain embodiments, the tapering outer face has a maximum outer diameter146. Tn certain embodiments, the hole122in the workpiece124has a minimum inner diameter. In certain embodiments, the maximum outer diameter146is greater than that of the minimum inner diameter of the hole122in the workpiece124. Tn certain embodiment, the taper134can extend for the longitudinal length of the shank132. In certain embodiment, the taper134extends for at least a portion of the longitudinal length of the shank132.

In certain embodiments, a taper136is measured with reference to a centerline138of the threaded insert120. In the illustrated embodiment, the taper136corresponds to half of the magnitude of the taper134.

In certain embodiments, the threaded insert120comprises a thread forming screw thread140(e.g., asymmetrical thread). In certain embodiments, the thread forming screw thread140comprises 3, 5, or 7 lobes. In certain embodiments, the thread forming screw thread140is disposed in the tapering outer face of the shank132. In certain embodiments, the thread forming screw thread140has a pitch and a depth which are substantially the same. In certain embodiments, the thread forming screw thread140has a parabolic shape. In certain embodiments, the thread forming screw thread140is trilobular or pentalobular. In certain embodiments, the thread forming profile can have at least a partial section of the thread140designed as an asymmetrical thread (e.g., three-lobed). For example, the trilobular thread can have a cross-section with three-sides of equal thickness.

in certain embodiments, the thread forming screw thread140forms threads in the unthreaded, tapered hole122of the workpiece as the head126drives the shank132into the workpiece124. For example, in certain embodiments, the thread forming screw thread140roll-forms the threads in the unthreaded, tapered hole122of the workpiece124as the head126drives the shank132into the workpiece124pushing excess material out of the way by plastic deformation.

The formed threads in the hole122are sized and shaped to receive the fastener200. In certain embodiments, the thread forming screw thread140begins a distance144from a bottom surface of the head126. The shank132of the threaded insert120is generally completely received within a thickness164of the workpiece124in a general direction parallel to thickness164. In certain embodiments, the threaded insert120has a length142.

In certain embodiments, the aperture128in the head126extends through the shank132. For example, in the illustrated embodiment, the aperture128extends for the entire length of the shank132. In the illustrated embodiment, the aperture has a diameter152, In the illustrated embodiment, the diameter152is sized to receive a 10 mm fastener200. Of course the diameter152is not limited to the listed size and can have any other size (e.g., 8 mm, 12 mm, 14 mm, 16 mm, etc.). The aperture128is sized to receive the fastener200.

In certain embodiments, the threaded insert120comprises a countersink154formed at the top of the aperture128in the head126. In certain embodiments, the countersink154can insure that a fastener200(e.g., flat head screw, flat head bolt) sits flush to the head126. In certain embodiments, the countersink168produces a conical Opening for the hole122matching the angle of the fastener200so that when the fastener200is fully engaged, the head of the fastener200will sit flush or slightly below the surface of the threaded insert120.

In certain embodiments, the threaded insert120comprises a screw thread150. In certain embodiments, the screw thread150is disposed inside the tubular shank132.

In certain embodiments, the screw thread150has a pitch and a depth which are substantially the same. In certain embodiments, the screw thread150is configured to receive the fastener200.

FIG.8is side view of the threaded insert20,120with a threaded fastener200secured therein.FIG.9is a bottom perspective view of the threaded insert20,120fromFIG.8. In certain embodiments, the shank32,132has a tapering outer face with substantially the same angle of taper34,134as the taper60,160of the hole22,122in the workpiece24,124. Of course, the taper34,134of the shank32,132and the taper60,160of the hole22,122need not be the same. In certain embodiments, the taper34,134of the shank32,132is different from the taper60,160of the hole22,122. For example, in certain embodiments, the taper34,134of the shank32,132is within 1.5 degrees of the taper60,160of the hole22,122. In other embodiments, the taper34,134of the shank32,132is within 2 degrees of the taper60,160of the hole22,122. In other embodiments, the taper34,134of the shank32,132is within 2.5 degrees of the taper60,160of the hole22,122. In other embodiments, the taper34,134of the shank32,132is within 3 degrees of the taper60,160of the hole22,122. Other magnitudes of the difference between the taper34,134of the shank32,132and the taper60,160of the hole22,122fall within the scope of this disclosure.

FIG.10is another bottom perspective view of the threaded insert fromFIG.8,FIG.11is a bottom, side perspective view of the threaded insert fromFIG.8.FIG.12is a plan bottom view of the threaded insert fromFIG.8. In certain embodiments, the tapering outer face has a maximum outer diameter46,146greater than that of a minimum inner diameter of the hole22,122in the workpiece24.124. In certain embodiment, the taper34,134can extend for the longitudinal length of the shank32,132.

FIG.13is a top view of another embodiment of a threaded insert220adapted to be installed in an unthreaded, tapered hole222in a workpiece224formed of a cast material.FIG.14is a partial cross-section view through the threaded insert222ofFIG.13taken along lines14-44inFIG.13. In certain embodiments, the threaded insert220includes a taper234.FIG.15is a cross-section view through the threaded insert220ofFIG.14taken along lines15-15inFIG.14showing a relief274in a distal portion of the inside of the tubular shank232. The relief274can improve packaging for the threaded insert220. In certain embodiments, the relief274can have a minimum inner diameter270and a maximum outer diameter272.

FIG.16is a cross-section view through a workpiece224that was cast with a hole222configured to subsequently receive the threaded insert220ofFIGS.13-15without post-processing. In the illustrated embodiment, the hole222in the workpiece224has diameter262and a taper260. The threaded insert220disclosed herein is designed to be directly installed in the hole222of the workpiece224(e.g., non-ferrous castings) without requiring post-processing after the workpiece224is cast to machine the hole222removing any taper. In certain embodiments, the hole222has a taper260of 4 degrees. Of course the magnitude of the taper260is not limited to 4 degrees and can be above or below 4 degrees. For example, the taper260of the hole222can be 2 degrees, 2.5 degrees, 3 degrees, 3.5 degrees, 4.5 degrees, 5 degrees, 5.5 degrees, 6 degrees, 6.5 degrees, 7 degrees, etc. including values within and ranges of the listed values.

In certain embodiments, the workpiece224comprises a countersink268formed at the top of the hole222. In certain embodiments, the countersink268can insure that the threaded insert220is easy to align with the hole222. In certain embodiments, the countersink268can be deep or shallow relative to the workpiece224. In certain embodiments, a bottom of the hole222comprises a radius266.

In certain embodiments, the threaded insert220includes a head226and a shank232. In the illustrated embodiments, a radius248joins surfaces of the head226and the shank232. The head226can comprise aperture228configured for a fastener200to be inserted therein after the threaded insert220is installed in the workpiece224. In certain embodiments, the threaded insert220is made of a higher tensile strength and harder material than the workpiece224, such as a steel, including stainless or spring steel. Of course other materials for the threaded insert220fall within the scope of this disclosure.

The fastener200can be any type of threaded fastener such as a screw or bolt, etc. Of course the fastener200can be a different type of fastener (e.g., plug, keyway, etc.) that is complementary to the internal channel within the threaded insert220. In exemplary use, the fastener200can provide hold-down capability to engage another item (not shown) to the workpiece224, or can act as an electrical contact post or electrical connection for the workpiece224.

The head226can include a driving arrangement230. The driving arrangement230can be sized and shaped to be engaged by a wrench, ratchet, drill, impact wrench, hex, or other driving tool known to a person having ordinary skill in the art. Air powered or pneumatic tools are also within the scope of this disclosure. In the illustrated embodiment, the driving arrangement230is a hex head.

The shank232can have a generally tubular or hollow shape. For example, in certain embodiments, the shank232includes an internal channel. In certain embodiments, the shank232has a tapering outer face. In certain embodiments, the shank232has substantially the same angle of taper234as the taper260of the hole222in the workpiece224. Of course, the taper234of the shank232and the taper260of the hole222need not be the same. In certain embodiments, the taper234of the shank232is different from the taper260of the hole222. For example, in certain embodiments, the taper234of the shank232is within 1.5 degrees of the taper260of the hole222. In other embodiments, the taper234of the shank232is within 2 degrees of the taper260of the hole222. In other embodiments, the taper234of the shank232is within 2.5 degrees of the taper260of the hole222. In other embodiments, the taper234of the shank232is within 3 degrees of the taper260of the hole222. Other magnitudes of the difference between the taper234of the shank232and the taper260of the hole222fall within the scope of this disclosure.

In certain embodiments, the tapering outer face has a maximum outer diameter246. In certain embodiments, the hole222in the workpiece224has a minimum inner diameter. In certain embodiments, the maximum outer diameter246is greater than that of the minimum inner diameter of the hole222in the workpiece224. In certain embodiment, the taper234can extend for the longitudinal length of the shank232. In certain embodiment, the taper234extends for at least a portion of the longitudinal length of the shank232.

In certain embodiments, a taper236is measured with reference to a centerline238of the threaded insert220. In the illustrated embodiment, the taper236corresponds to half of the magnitude of the taper234.

In certain embodiments, the threaded insert220comprises a thread forming screw thread240(e.g., asymmetrical thread). In certain embodiments, the thread forming screw thread240comprises 3, 5, or 7 lobes. In certain embodiments, the thread forming screw thread240is disposed in the tapering outer face of the shank232. In certain embodiments, the thread forming screw thread240has a pitch and a depth which are substantially the same. In certain embodiments, the thread forming screw thread240has a parabolic shape. In certain embodiments, the thread forming screw thread240is trilobular or pentalobular. In certain embodiments, the thread forming profile can have at least a partial section of the thread240designed as an asymmetrical thread (e.g., three-lobed). For example, the trilobular thread can have a cross-section with three-sides of equal thickness.

In certain embodiments, the thread forming screw thread240forms threads in the unthreaded, tapered hole222of the workpiece as the head226drives the shank232into the workpiece224. For example, in certain embodiments, the thread forming screw thread240roll-forms the threads in the unthreaded, tapered hole222of the workpiece224as the head226drives the shank232into the workpiece224pushing excess material out of the way by plastic deformation.

The formed threads in the hole222are sized and shaped to receive the fastener200. In certain embodiments, the thread forming screw thread240begins a distance244from a bottom surface of the head226. The shank232of the threaded insert220is generally completely received within a thickness264of the workpiece224in a general direction parallel to thickness264. In certain embodiments, the threaded insert220has a length242.

In certain embodiments, the aperture228in the head226extends through the shank232. For example, in the illustrated embodiment, the aperture228extends for the entire length of the shank232. In the illustrated embodiment, the aperture has a diameter252. In the illustrated embodiment, the diameter252is sized to receive a 10 mm fastener200. Of course the diameter252is not limited to the listed size and can have any other size (e.g., 8 mm, 12 mm, 14 mm, 16 mm, etc.). The aperture228is sized to receive the fastener200.

In certain embodiments, the threaded insert220comprises a countersink254formed at the top of the aperture228in the head226. In certain embodiments, the countersink254can insure that a fastener200(e.g., flat head screw, flat head bolt) sits flush to the head226. In certain embodiments, the countersink268produces a conical opening for the hole222matching the angle of the fastener200so that when the fastener200is fully engaged, the head of the fastener200will sit flush or slightly below the surface of the threaded insert220.

In certain embodiments, the threaded insert220comprises a screw thread250. In certain embodiments, the screw thread250is disposed inside the tubular shank232. In certain embodiments, the screw thread250has a pitch and a depth which are substantially the same. In certain embodiments, the screw thread250is configured to receive the fastener200.

FIG.17is a top view of a tapered fastener in the form of a screw320adapted to be installed in an unthreaded, tapered hole322(FIG.19) in a workpiece324. In certain embodiments, the workpiece24is formed of a cast material.FIG.18is a side view of the screw320ofFIG.17. In certain embodiments, the screw320includes a taper334.FIG.19is a cross-section view through a workpiece324that was cast with a hole322configured to subsequently receive the screw320ofFIGS.17and18. In the illustrated embodiment, the hole322in the workpiece324has diameter362and a taper360. The screw320disclosed herein are designed to be directly installed in the hole322of the workpiece324(e.g., non-ferrous castings) without requiring post-processing to machine the hole322after casting the workpiece324. For, example, the screw320disclosed herein can be aligned and driven into the hole322without having to machine the hole to cut away the as-cast taper of the hole322.

In certain embodiments, the hole322has a taper360of about 4 degrees. Of course the magnitude of the taper360is not limited to 4 degrees and can be above or below 4 degrees. For example, the taper360of the hole322can be 2 degrees, 2.5 degrees, 3 degrees, 3.5 degrees, 4.5 degrees, 5 degrees, 5.5 degrees, 6 degrees, 6.5 degrees, 7 degrees, etc. including values within and ranges of the listed values.

In certain embodiments, the workpiece324comprises a countersink368formed at the top of the hole322. In certain embodiments, the countersink368can insure that the screw320is easy to align with the hole322. In certain embodiments, a bottom of the hole322comprises a radius366.

in certain embodiments, the screw320includes a head326and a shank332. In the illustrated embodiments, a radius348joins surfaces of the head326and the shank332. In certain embodiments, the screw320is made of a higher tensile strength and harder material than the workpiece324, such as a steel, including stainless or spring steel. Of course other materials for the screw320fall within the scope of this disclosure.

The screw320can provide hold-down capability to engage another item (not shown) to the workpiece324.

The head326can include a driving arrangement330. The driving arrangement330can be sized and shaped to be engaged by a wrench, ratchet, drill, impact wrench, or other driving tool known to a person having ordinary skill in the art. Air powered or pneumatic tools are also within the scope of this disclosure.

The shank332can have a generally tubular. In certain embodiments, the shank332has a tapering outer face. In certain embodiments, the shank332has substantially the same angle of taper334as the taper360of the hole322in the workpiece324. Of course, the taper334of the shank332and the taper360of the hole322need not be the same. In certain embodiments, the taper334of the shank332is different from the taper360of the hole322. For example, in certain embodiments, the taper334of the shank332is within 1.5 degrees of the taper360of the hole322. In other embodiments, the taper334of the shank332is within 2 degrees of the taper360of the hole322. In other embodiments, the taper334of the shank332is within 2.5 degrees of the taper360of the hole322. In other embodiments, the taper334of the shank332is within 3 degrees of the taper360of the hole322. Other magnitudes of the difference between the taper334of the shank332and the taper360of the hole322fall within the scope of this disclosure.

In certain embodiments, the tapering outer face has a maximum outer diameter346. In certain embodiments, the hole322in the workpiece324has a minimum inner diameter. In certain embodiments, the maximum outer diameter346is greater than that of the minimum inner diameter of the hole322in the workpiece324. In certain embodiment, the taper334can extend for the longitudinal length of the shank332. In certain embodiment, the taper334extends for at least a portion of the longitudinal length of the shank332.

In certain embodiments, the screw320comprises a thread forming screw thread340(e.g., asymmetrical thread). In certain embodiments, the thread forming screw thread340comprises 3, 5, or 7 lobes. In certain embodiments, the thread forming screw thread340is disposed in the tapering outer face of the shank332. In certain embodiments, the thread forming screw thread340has a pitch and a depth which are substantially the same.

In certain embodiments, the thread forming screw thread340has a parabolic shape. In certain embodiments, the thread forming screw thread340is trilobular or pentalobular. In certain embodiments, the thread forming profile can have at least a partial section of the thread340designed as an asymmetrical thread (e.g., three-lobed). For example, a trilobular thread can have a cross-section with three-sides of equal thickness.

In certain embodiments, the thread forming screw thread340forms threads in the unthreaded, tapered hole322of the workpiece as the head326drives the shank332into the workpiece324. For example, in certain embodiments, the thread forming screw thread340roll-forms the threads in the unthreaded, tapered hole322of the workpiece324as the head326drives the shank332into the workpiece324pushing excess material out of the way by plastic deformation.

In certain embodiments, the thread forming screw thread340begins a distance344from a bottom surface of the head326. The shank332of the screw320is generally completely received within a thickness364of the workpiece324in a general direction parallel to the thickness364. In certain embodiments, the screw320has a length342.

The head326can include a driving arrangement330, The driving arrangement330can be sized and shaped to be engaged by a wrench, ratchet, drill, impact wrench, hex, or other driving tool known to a person having ordinary skill in the art. Air powered or pneumatic tools are also within the scope of this disclosure.

FIG.20is a top view of a tapered fastener in the form of a double ended stud420adapted to be installed in an unthreaded, tapered hole422(FIG.22) in a workpiece424. In certain embodiments, the workpiece424is formed of a cast material.FIG.21is a side view of the double ended stud420ofFIG.20. In certain embodiments, the double ended stud420includes a taper434.FIG.22is a cross-section view through a workpiece424that was cast with a hole422configured to subsequently receive the double ended stud420ofFIGS.20and21. In the illustrated embodiment, the hole422in the workpiece424has diameter462and a taper460. The double ended stud420disclosed herein is designed to be directly installed in the hole422of the workpiece424(e.g., non-ferrous castings) without requiring post-processing to machine the hole422after casting the workpiece424. For, example, the double ended stud420disclosed herein can be aligned and driven into the hole422without having to machine the hole to cut away the as-cast taper of the hole422.

In certain embodiments, the hole422has a taper460of about 4 degrees. Of course the magnitude of the taper460is not limited to 4 degrees and can be above or below 4 degrees. For example, the taper460of the hole422can be 2 degrees, 2.5 degrees, 3 degrees, 3.5 degrees, 4.5 degrees, 5 degrees, 5.5 degrees, 6 degrees, 6.5 degrees, 7 degrees, etc. including values within and ranges of the listed values.

In certain embodiments, the workpiece424comprises a countersink468formed at the top of the hole422. In certain embodiments, the countersink468can insure that the double ended stud420is easy to align with the hole422. In certain embodiments, a bottom of the hole422comprises a radius466.

In certain embodiments, the double ended stud420includes a head426, a shank432, and a stud470. In certain embodiments, the stud470can be plain or threaded. In the illustrated embodiments, a radius448joins surfaces of the head426and the shank432. In certain embodiments, the double ended stud420is made of a higher tensile strength and harder material than the workpiece424, such as a steel, including stainless or spring steel. Of course other materials for the double ended stud420fall within the scope of this disclosure.

The double ended stud420can provide the stud470to couple another item (not shown) the workpiece424.

The head426can include a driving arrangement430. The driving arrangement430can be sized and shaped to be engaged by a wrench, ratchet, drill, impact wrench, or other driving tool known to a person having ordinary skill in the art. Air powered or pneumatic-tools are also within the scope of this disclosure.

The shank432can have a generally tubular. In certain embodiments, the shank432has a tapering outer face. In certain embodiments, the shank432has substantially the same angle of taper434as the taper460of the hole422in the workpiece424. Of course, the taper434of the shank432and the taper460of the hole422. need not be the same. In certain embodiments, the taper434of the shank432is different from the taper460of the hole422. For example, in certain embodiments, the taper434of the shank432is within 1.5 degrees of the taper460of the hole422. In other embodiments, the taper434of the shank432is within 2 degrees of the taper460of the hole422. In other embodiments, the taper434of the shank432is within 2.5 degrees of the taper460of the hole422. In other embodiments, the taper434of the shank432is within 3 degrees of the taper460of the hole422. Other magnitudes of the difference between the taper434of the shank432and the taper460of the hole422fall within the scope of this disclosure.

In certain embodiments, the tapering outer face has a maximum outer diameter446. In certain embodiments, the hole422in the workpiece424has a minimum inner diameter. In certain embodiments, the maximum outer diameter446is greater than that of the minimum inner diameter of the hole422in the workpiece424. In certain embodiment, the taper434can extend for the longitudinal length of the shank432. In certain embodiment, the taper434extends for at least a portion of the longitudinal length of the shank432.

In certain embodiments, the double ended stud420comprises a thread forming screw thread440(e.g., asymmetrical thread). In certain embodiments, the thread forming screw thread440comprises 3, 5, or 7 lobes. In certain embodiments, the thread forming screw thread440is disposed in the tapering outer face of the shank432. In certain embodiments, the thread forming screw thread440has a pitch and a depth which are substantially the same. In certain embodiments, the thread forming screw thread440has a parabolic shape. In certain embodiments, the thread forming screw thread440is trilobular or pentalobular. In certain embodiments, the thread forming profile can have at least a partial section of the thread440designed as an asymmetrical thread (e.g., three-lobed). For example, a tri lobular thread can have a cross-section with three-sides of equal thickness.

In certain embodiments, the thread forming screw thread440forms threads in the unthreaded, tapered hole422of the workpiece as the head426drives the shank432into the workpiece424. For example, in certain embodiments, the thread forming screw thread440roll-forms the threads in the unthreaded, tapered hole422of the workpiece424as the head426drives the shank432into the workpiece424pushing excess material out of the way by plastic deformation.

The shank432of the double ended stud420is generally completely received within a thickness464of the workpiece424in a general direction parallel to the thickness464. In certain embodiments, the double ended stud420has a length442.

The head426can include a driving arrangement430. The driving arrangement430can be sized and shaped to be engaged by a wrench, ratchet, drill, impact wrench, hex, or other driving tool known to a person having ordinary skill in the art. Air powered or pneumatic tools are also within the scope of this disclosure.

In the foregoing specification, the disclosure has been described with reference to specific embodiments. However, as one skilled in the art will appreciate, various embodiments disclosed herein can be modified or otherwise implemented in various other ways without departing from the spirit and scope of the disclosure. Accordingly, this description is to be considered as illustrative and is for the purpose of teaching those skilled in the art the manner of making and using various embodiments of the disclosed glove box actuation assembly. It is to be understood that the forms of disclosure herein shown and described are to be taken as representative embodiments. Equivalent elements, materials, processes or steps may be substituted for those representatively illustrated and described herein. Moreover, certain features of the disclosure may be utilized independently of the use of other features, all as would be apparent to one skilled in the art after having the benefit of this description of the disclosure. Expressions such as “including”, “comprising”, “incorporating”, “consisting of”, “have”, “is” used to describe and claim the present disclosure are intended to be construed in a non-exclusive manner, namely allowing for items, components or elements not explicitly described also to be present. Reference to the singular is also to be construed to relate to the plural.

Further, various embodiments disclosed herein are to be taken in the illustrative and explanatory sense, and should in no way be construed as limiting of the present disclosure. All joinder references (e.g., attached, affixed, coupled, connected, and the like) are only used to aid the reader's understanding of the present disclosure, and may not create limitations, particularly as to the position, orientation, or use of the systems and/or methods disclosed herein. Therefore, joinder references, if any, are to be construed broadly. Moreover, such joinder references do not necessarily infer that two elements are directly connected to each other. Additionally, all numerical terms, such as, but not limited to, “first”, “second”, “third”, “primary”, “secondary”, “main” or any other ordinary and/or numerical terms, should also be taken only as identifiers, to assist the reader's understanding of the various elements, embodiments, variations and/or modifications of the present disclosure, and may not create any limitations, particularly as to the order, or preference, of any element, embodiment, variation and/or modification relative to, or over, another element, embodiment, variation and/or modification.