EXPANDED THREADED INSERTS

Abstract: An insert (10) has a tubular body (14) with a cylindrical outside surface and a threaded inside surface (22). A tubular extension (15) extends axially from the body (14) and includes a radially outwardly opening girth groove (16). A tapered lock ring (12) is positioned within the groove (16) with its large diameter end (26) against a side surface (28) of a member (20). The insert (10) with lock ring (12) attached, is installed in an opening (18) in the member (20). Then, a mandrel (M) is pulled through the tubular body (14) for radially expanding the tubular body so as to anchor it within the opening (18) and connect it to the member (20).

Description: Description EXPANDED THREADED INSERTS Cross Reference to Related Application This application claims priority based on provisional patent application number 60/066,267, filed November 20, 1997 and entitled Expanded Threaded Inserts. Technical Field The present invention relates to fastener receiving inserts for openings in structural members. More particularly, it relates to a provision of an internally threaded insert that can be installed from one side of the member, and which can be radially expanded in the opening to secure it to the member and resist torque and pull-out resistance under load. The invention also relates to the provision of a method for securing the insert in an opening in a member. Background of the Invention The background of what may be termed the "nut-plate technology" is discussed in U.S. Patent No. 5,096,349, granted March 17, 1992, to Michael A. Landy et al . , and in U.S. Patent No. 5,245,743, granted September 21, 1993, to Michael A. Landy et al . , and in U.S. Patent No. 5,380,136, granted January 10, 1995 to Charles M. Copple et al . , and in U.S. Patent No. 5,405,228, granted April 11, 1995, to Leonard F. Reid et al . , and in U.S. Patent No. 5,468,104, granted November 21, 1995, to Leonard F. Reid et al . These patents disclose nut mounting structures characterized by a tubular stem that fits into an opening in a wall where a bolt is to be located. The tubular stem is radially expanded within the opening to connect the nut mounting structure to the wall. The tooling and methods disclosed in these patents for expanding the tubular stem are to be considered a part of the present disclosure. Thus, the disclosures of the above-referenced patents are hereby incorporated herein by this specific reference to them. There is a need for a bolt receiving insert that is expandable within an opening in a member to connect it to the member, and which is itself internally threaded so that a separate nut is unnecessary. There is a need for a bolt receiving insert that can be inserted into an opening in a composite structure with no access to the back side. The insert must be insertable from the front side of the structure and then be expandable in the opening by use of tooling positioned only on the front side of the structure. A purpose of such an insert is to facilitate attachment of a panel or other member to a parent structure using a threaded bolt . The insert must resist torque loading from the bolt and pull-out due to the axially load during torque-up of the bolt. There is further a need for a bolt receiving insert that is adapted for easy and quick placement and retention within an opening in a member. There is also a need for a bolt receiving insert that is sealed and will provide a sealed closure for the opening when no bolt is connected to the insert. It is believed that the bolt receiving insert of this invention will fulfill these needs. Disclosure of the Invention A fastener element or insert of the invention is basically characterized by a tubular body having a cylindrical outside surface and a threaded inside surface. A tubular extension extends axially from one end of the body and includes a radially outwardly opening girth groove. A lock ring is retained in the girth groove. The lock ring has a free state external diameter that is larger than the outside diameter of the tubular body. The tubular body is inserted through an opening in a member and moved to place the lock ring substantially against the near side of the member. Then, the tubular body is radially expanded to hold it into the opening. Thereafter, a bolt is connected to the tubular body by engaging its threads with the threaded inside surface of the tubular body . In preferred form, the lock ring tapers as it extends axially outwardly from the body. It tapers down to a diameter at its outer end that is substantially equal to the external diameter of the tubular extension. The lock ring is split to form a radial gap. This allows the lock ring to be expanded for insertion on the fastener element. Preferably also, the lock ring and girth groove are adapted to permit the lock ring to be radially compressed into the girth groove. This allows the fastener element to be inserted into an opening in a member with the extension leading until the tapered lock ring is in contact with the periphery of the opening. Then, the fastener element is forced endwise towards the member to force the lock ring into an through the opening in the member. Contact between the periphery of the opening and the tapered surface of the lock ring serves to compress the lock ring radially inwardly, allowing it to move into and through the opening in the member. Once the lock ring has passed entirely through the opening, it will expand radially in the girth groove to place its trailing end surface closely adjacent the second side of the member. Once expanded, the lock ring will prevent the fastener element from being pulled back out of the opening. According to the invention, the tubular extension can have either an open outer end or a closed outer end. A closed outer end will provide a sealed connection. The closed extension end of the tubular insert may be sufficiently long that it can receive a mandrel end portion, inserted into it through the tubular body, so that a pull on the mandrel can be used to radially expand the tubular body for securing it within the opening . According to another aspect of the invention, the lock ring may be a radially flat ring that is inserted into a complementary girth groove after the fastener element has been positioned within the opening with the girth groove on the second side of the member. According to an aspect of the invention, the fastener element is used with a composite structure. The member is constructed from a composite material and an opening is formed in the member. The tubular body of the fastener element is inserted into the opening and the tubular body is radially expanded to secure it to the composite material surrounding the opening . According to the invention, the fastener element can be installed in an opening in a member from a single side of the member. The fastener element is placed on the small diameter portion of a mandrel that is attached to a puller tool. Then, a large diameter leading portion of the mandrel is aligned with an opening in a member and is then pushed forwardly to move it into and through the opening and position the tubular body in the opening. Then, the puller tool is operated to pull the mandrel back through the fastener element while holding the fastener element within the opening. An increasing diameter portion of the mandrel is pulled through the tubular body of the fastener element by the puller tool. In the process, the increasing diameter portion of the mandrel exerts a radially outwardly directed force on the tubular body, expanding it in the opening, to create a secure interference fit between the outside surface of the tubular body and the adjacent inside surface of the opening. In preferred form, a tapered lock ring is used to hold the fastener element against axial movement while the mandrel is being pulled through the tubular body. It is within the scope of the invention to use a mandrel plus what sleeve, a mandrel only, or a split mandrel for radially expanding the tubular body to anchor the fastener element in the opening. A part of the invention was the discovery that an internally threaded tubular insert can be expanded radially to anchor it within an opening in a member, by use of expansion tooling, without the internal threads being damaged. Nevertheless, it is contemplated by the present invention to dress the threads following the expansion, if some dressing should be necessary. The invention further includes providing the threads with a protective sleeve that can be removed after the fastener element is expanded and secured to the member. Other objects, features and advantages of the invention will be hereinafter described in greater detail, as a part of the description of the best mode and the alternative embodiments of the invention. Brief Description of the Drawings Like reference numerals are used to designate like parts throughout the various figures of the drawing, wherein: Fig. 1 is a pictorial view of a typical embodiment of the fastener element or insert, shown with a conical lock ring attached, such view being taken from above and looking towards one side and the rear end of the insert; Fig. 2 is an exploded pictorial view of the fastener element, showing the lock ring positioned endwise from the rest of the element, such view showing a preferred shape of the lock ring and a preferred shape of the annular channel or girth groove that receives the lock ring, such view being taken from above and looking towards one side and the extension end of the fastener element; Fig. 3 is a longitudinal sectional view taken through the fastener element, but with the lock ring omitted, such view showing internal threads in the tubular body; Fig. 4 is a side elevational view of the structure shown by Fig. 3, including dimension lines; Fig. 5 is a side elevational view of the lock ring for the fastener element shown by Figs. 3 and 4, such view including dimension lines; Fig. 6 is a longitudinal sectional view of the fastener insert of Figs. 1-5 after it is anchored within an opening within a member; Fig. 7 is a fragmentary view similar to Fig. 6, but showing a radially flat lock ring within a much narrower girth groove in the extension of the fastener element; Figs. 8-14 are diagrams of the major steps of the invention; and Fig. 15 is a view like Fig. 6, but of a modified form of fastener element, such fastener element having a closed outer end to provide a dome on the lock ring end of the fastener element . Best Mode for Carrying Out the Invention Figs. 1-6 show a preferred form of the fastener element or insert 10. It comprises a body portion 14 having an axial extension 15 which includes an annular channel or girth groove 16 on its outer surface. As shown by Figs. 1-4 and 6, the girth groove 16 opens radially outwardly. The girth groove 16 is provided to receive a lock ring which in the preferred embodiment is shown in the form of a tapered ring 12 that is split radially. The split is designated 13 in Figs. 1 and 2. Fig. 6 shows the insert 10 within an opening 18 in a member 20. For example, member 20 may be constructed from a structural plastic or composite material. While it is desirable to use the insert 10 in composite material, it can be used in metal or other materials as well. The lock ring 12 may be positioned within the girth groove 16, in the manner shown by Figs. 1 and 6. The presence of the split 13 makes is possible to open up the lock ring 12 and snap fit it onto the insert 10, within the girth groove 12. The lock ring 12 has a large diameter end 26 that is adjacent the tubular body 14. It also has a small diameter opposite end. As clearly illustrated, it decreases in diameter (tapers) from its large end 26 to its opposite end 27. As shown in Fig. 6, the lock ring 12 preferably has an inside diameter 29 that is larger than the outside diameter of girth groove 16. This provides a radial space between the lock ring 12 and the girth groove 16, into which the lock ring 12 can be radially compressed. In accordance with an aspect of the invention, the lock ring 12 is positioned on the insert 10, with its inner portion within the girth groove 16. When lock ring 12 is not compressed, it has a static outside dimension that places a portion of it outside of the outer surface of the tubular body 14. This portion includes an outer portion of radial surface 26, shown in Fig. 6 to be positioned against surface 28 of member 20. After lock ring 12 is installed on the insert 10, the extension end of insert 10 is brought into alignment with the opening 18, on a first side of the member 20. The outside diameter of extension 15, at its outer end, is smaller than the outside diameter of the body portion 14 and is also smaller than the diameter of the opening 18. As a result, extension 15 can fit easily into the opening 18. After extension 15 is started in an opening 18, the insert 10, with lock ring 12 attached, is moved endwise inwardly until the sloping outer surface of the lock ring 12 contacts the periphery of the opening 18. Then, it becomes necessary to forcefully move the insert 10 into the opening 18. When forced, insert 10 will move axially and in the process the periphery of the opening 18 will exert a squeezing force on the lock ring 18, compressing it radially and moving it further into the girth groove 16. The parts are dimensioned such that the lock ring 12 will compress sufficiently to allow it and the rest of insert 10 to move first into and then through the opening 18. Once lock ring 12 has moved out from the opening 18 at the second end of the member 20, it will resume its original static shape. When compressed, it is in the nature of a spring. The stored spring energy returns the lock ring 12 to its static shape once the outer surface of ring 12 loses contact with the periphery of opening 18. As shown by Fig. 6, the lock ring 12 expands to place the outer region of radial surface 26 into abutting contact with the surface 28 on the second side of member 20. Any type of system for radially expanding the insert 10 can be used for connecting the insert 10 to the member 20. These systems include a mandrel only system, a split mandrel system, and a mandrel and sleeve system. The mandrel, when a mandrel alone is use, or the split sleeve, when a split sleeve is used, directly contact the threads 22. When a split sleeve is used, it provides some protection for the threads . By way of typical and therefore nonlimitive example, some dimensions are given in Figs. 4 and 5. The dimensions present an example of tolerances and clearances that may be used in the system. Referring to Fig. 4, dimension Dl may be 0.341 +.002 inches. Dimension D2 may be 0.255 +.003 inches. Dimension D3 may be 0.030 ± .005 inches. Dimension D4 may be 0.100 ± .005 inches. Dimension D5 may be 0.285 ± .003 inches. Dimension D6 may be 0.235 + .00 / -.005. Dimension D7 may 0.3425 + .0007 inches. The threads 22 may be 1/4-28UNF-2B threads. After tapping, the finished threads may minor to 0.228 ± .001 inches. Referring to Fig. 5, dimension D8 may be 0.320 + .002. Dimension D9 may be 0.310 + .002 inches. Dimension D10 may be 0.090 ± .005 inches. Dimension Dll may be 0.360 + .002 inches. Angle A may be 12.5°. Angle B may be 45° X.010-.015. Insert 10 may be made from various materials, including 17.4 stainless steel. Tubular body 14 may be provided with a sand blasted outside surface. Slot 13 may be about 0.060 ± .005 inches wide. The lock ring 12 may be made from 17-4 stainless steel, with a H 102 condition. The finish may be RMS 64 or better. As illustrated, the taper on the tapered split ring 12 is slight. The radial surface 26 projects radially outwardly from the tubular body 14 a small distance. This is all that is necessary. The taper provides a good lead-in for the ring 12. The surface 26 provides a lock surface for locking the insert 10 within the opening 18. Instead of the ring 12 and groove 16, a thinner groove 16' can be used and the lock ring 12' may be flat, and may be like or similar to the ring 14 disclosed in the aforementioned U.S. Patent No. 5,380,136 which has already been incorporated herein by reference. The groove 16' may be like the snap ring groove disclosed in the same patent. In order to use the snap ring 12', there must be access to both sides of the work piece 20. The insert 10' can be installed from one side of the workpiece, the side where the mandrel puller is located. Insert 10' may also be used if access is available to both sides of the workpiece. In this case, an integral radial flange on one end of the insert can be provided in lieu of the snap-ring 12' or the conical ring 12. See, for example, elements 428 and 429 in Fig. 25 of U.S. Patent No. 5,380,136. A circular flange 429 would be preferred. Figs. 8-14 illustrate a preferred method of installing the insert 10 within an opening 18 in a member 20. This method will now be described with reference to Figs. 8-14: 1. A split sleeve S of the appropriate dimension (diameter, thickness, length etc.) Is placed over the major diameter of a specially sized expansion mandrel M and along the minor diameter of the mandrel M until it is seated against the inner jaw of a uniquely designed nosecap assembly on puller P. The split sleeve S may or may not have a flared end. If the sleeve S is flared, the sleeve S must be oriented so that the flare is against the nosecap. 2. The Composite Threaded Insert Assembly (insert body and slotted conical ring) is then slid onto the mandrel M and over the seated split sleeve S until it is against the nosecap as well. The insert assembly should be oriented so that the straight portion of the insert body, intended for mating with the starting hole in the parent material and commonly referred to as the insert barrel, is against the nosecap and the flange restraining the slotted conical ring is away from the nosecap. 3. The entire installation assembly, including the mandrel M, split sleeve S and composite threaded insert, is guided into a purpose prepared, precisely dimensioned starting hole in the intended parent structure 20 so that the flange retaining the slotted conical ring is fitted into the bore of the hole. 4. Once placed part way into the starting hole, a modest force is applied to the installation tooling and composite threaded insert assembly by the operator to fit the mandrel M, insert 10 and sleeve S through the hole 18 and the nosecap up against the parent structure. During this operation the slotted conical ring 12 is compressed into a groove 16 on the outside diameter of the insert body 14 and can be passed through the bore of the starting hole. Upon exiting the starting hole on the opposite side of the parent structure 20, the slotted conical ring 12 springs open again and provides a flange to prevent the composite threaded insert 10 from being drawn back through the parent structure 20 during the fastener clamp up. 5. After the composite threaded insert 10, mandrel M and sleeve S have been guided through the starting hole 18, and the nosecap is up against the surface of the parent structure 20, the hydraulic puller unit P is activated to draw the major diameter of the mandrel M through the split sleeve and inside diameter of the insert body 14. The insert body 14 itself is permanently deformed by the subsequent radial expansion and the insert barrel grows in diameter so that it becomes interference fit with the wall of the starting hole. 6. When the mandrel M has passed inside the nosecap, the composite threaded insert 10 has been successfully installed and the installation tooling may be removed. The deformed split sleeve S may be still present in the inside diameter of the insert body after installation. This sleeve S is removed by hand or with a small tool (pliers etc. whatever is convenient) and the composite threaded insert 10 is ready for use. Fig. 15 shows a modified insert 10' ' that is like insert 10 except that the extension 15 includes a closed, domed shaped end portion 30. The dome 30 closes the split ring side of the insert 10''. The insert 10'' may be used when a leak proof joint is desired. Also, a 0-ring may be placed between the insert 10'' and the opening 18, to enhance sealing. A short- ended mandrel 63 can be used for installing the insert 10''. An end portion of the mandrel 63 is shown by phantom line in Fig. 15. As should be apparent, the puller P is on the side of the member 20 opposite the doom 30. An internally threaded insert is fabricated with an extended groove on one end to accommodate a conical split ring which has free state external diameter slightly larger than the outside diameter of the insert. The conical split ring can be compressed to the same outside diameter to enable the ring end of the insert to be placed through the hole from the front side and pushed through the slightly cleared hole. The tapered conical section of the ring facilitates insertion and compression of the ring to slide through the hole. On exit from the backside of the hole the ring will expand - or spring back to its normal diameter thereby creating a restraint to prevent the insert from pulling back through the hole. The threaded insert is then cold expanded into the hole using lubricated sleeve and expansion mandrel combination similar to the current Fatigue Technology Inc. (FTI) BushLoc© or ForceTec® processes. Expansion of the insert into the hole creates a high interference fit of the insert into the hole which resists torque out of the insert. The conical split ring prevents the insert from pulling through the hole during the torque-up of the attaching bolt . During expansion of the threaded insert the threads are slightly deformed but not sufficient to prevent engagement of the threads on the mating attaching bolt or fastener. To preclude excessive damage to the threads inside the insert, a re-usable or sacrificial (one-time use) hollow, an externally threaded sleeve or liner also may be initially threaded into the insert to protect the threads. The lubricated split sleeve and expansion mandrel are then inserted through the hollow liner and then the liner and insert are expanded in place as described. The threaded liner would be necessary when expansion is effected by a split mandrel or a solid mandrel method to prevent engagement of the expansion devices in the threads of the insert. The subject threaded liner is removed from the insert after expansion. Initial testing of the invention has shown very high resistance to torque-out and pull-out when installed in both carbon fiber and Kevlar-carbon fiber plates ranging from 0.115" to 0.155" thick. The illustrated embodiments are only examples of the present invention and, therefore, are non-limitive . It is to be understood that many changes in the particular structure, materials and features of the invention may be made without departing from the spirit and scope of the invention. Therefore, it is my intention that my patent rights not be limited by the particular embodiments illustrated and described herein, but rather determined by the following claims, interpreted according to accepted doctrines of claim interpretation, including use of the doctrine of equivalents and reversal of parts.

Claims: What is claimed is : 1. A fastener element, comprising: a tubular body having a cylindrical outside surface and a threaded inside surface; a tubular extension on said body extending axially from said body, said tubular extension including a radially outwardly opening girth groove ; and a lock ring in said girth groove having a free state external diameter that is larger than the outside diameter of the tubular body, whereby the tubular body can be positioned within an opening in a member, with the lock ring against a side of the member, and the tubular body can be radially expanded to hold it in the opening, and a bolt can be connected to the threaded inside surface. 2. The fastener element of claim 1, wherein the lock ring tapers as it extends axially outwardly. 3. The fastener element of claim 2, wherein the lock ring tapers down to a diameter at its outer end that is substantially equal to the external diameter of the tubular extension . 4. The fastener element of claim 1, wherein the lock ring is substantially flat in the radial direction. 5. The fastener element of claim 1, wherein the lock ring is a split ring. 6. The fastener element of claim 5, wherein the external diameter of the lock ring decreases as the lock ring extends axially outwardly. 7. The fastener element of claim 6, wherein the lock ring tapers down to a diameter at its outer end that is substantially equal to the external diameter of the tubular extension. 8. The fastener element of claim 1, wherein the tubular extension has a closed outer end, said extension including a closed internal chamber. 9. The fastener element of claim 8, wherein the external diameter of the lock ring decreases as the lock ring extends axially outwardly. 10. A bolt receiving insert for an opening in a member, comprising: a tubular body sized to be insertable into the opening, said tubular body being constructed from a material allowing it to be radially expanded once in the opening, to lock it within such opening; a tubular extension on said body extending axially from said body, said tubular extension including a radially outwardly opening girth groove; a lock ring in said girth groove having a static outside diameter larger than the outside diameter of the tubular body; whereby the tubular body of the insert can be positioned within the opening, with the lock ring against the member, and said tubular body can be radially expanded to hold it in the opening; and said tubular body having internal threads, whereby after the tubular body is radially expanded to hold it in the opening, a bolt can be threaded into the threaded opening. 11. The fastener element of claim 10, wherein the external diameter of the lock ring decreases as the lock ring extends axially outwardly in the girth groove. 12. The fastener element of claim 11, wherein the lock ring tapers down to a diameter at its outer end that is substantially equal to the external diameter of the tubular extension . 13. The fastener element of claim 10, wherein the lock ring is substantially flat in the radial direction. 14. The fastener element of claim 10, wherein the lock ring is a split ring. 15. In combination, a composite member having first and second sides and a through opening extending between the first and second sides; an insert for said opening, comprising: a tubular body in said opening having a cylindrical outside surface and a threaded inside surface; a tubular extension on said body extending axially from said body, said tubular extension including a radially outwardly opening girth groove ; and a lock ring in said girth groove having a free state external diameter that is larger than the outside diameter of the tubular body, whereby the tubular body is positioned within the opening in the composite member and is moved to place the lock ring against a side of the member, and the tubular body is radially expanded to hold it in the opening, and whereby a bolt can be connected to the threaded inside surface of the tubular body. 16. The fastener element of claim 15, wherein the lock ring has an external diameter that decreases as the lock ring extends axially outwardly. 17. The fastener element of claim 16, wherein the lock ring tapers down to a diameter at its outer end that is substantially equal to the external diameter of the tubular extension. 18. The fastener element of claim 15, wherein the lock ring is substantially flat in the radial direction. 19. The fastener element of claim 15, wherein the lock ring is a split ring. 20. The fastener element of claim 19, wherein the external diameter of the lock ring decreases as the lock ring extends axially outwardly. 21. The fastener element of claim 20, wherein the lock ring tapers down to a diameter at its outer end that is substantially equal to the external diameter of the tubular extension. 22. A method of installing a bolt receiving insert in an opening in a member, comprising: providing a bolt receiving insert having a tubular body with a cylindrical outside surface and a threaded inside surface, and a tubular extension on said body extending axially from said body and including a radially outwardly opening girth groove ; positioning a lock ring in said girth groove, said lock ring having a free state external diameter that is larger than the outside diameter of the tubular body; positioning the tubular body in the opening in the member with the lock ring substantially against the side of the member; and radially expanding the tubular body to hold it in the opening, whereby a threaded portion of a bolt can be thread connected to the threaded inside surface of the tubular body, for connecting the bolt to the tubular body. 23. The method of claim 22, comprising providing a mandrel having a portion that increases in diameter, and radially expanding the tubular body by moving the mandrel axially through the tubular body, to cause the increasing diameter portion of the mandrel to exert an axially outwardly directed force on the tubular body. 24. The method of claim 22, comprising positioning a lock ring in said girth groove that has an external diameter that decreases as the lock ring extends axially outwardly, down to a diameter at its outer end that is substantially equal to the external diameter of the tubular extension, and inserting the bolt receiving insert into the opening in the member, extension end first, to move the lock ring into contact with a portion of the member surrounding the opening, and applying an endwise force on the insert to move the lock ring into and through the opening into a position where the lock ring is positioned outwardly adjacent the second side of the opening. 25. The method of claim 22, comprising providing a mandrel puller, a mandrel having a small diameter end connected to the puller, a larger diameter opposite end, and a tapered intermediate section, placing a split sleeve on the small diameter section of the mandrel, placing a said insert on the split sleeve while it is on the small diameter section of the mandrel, inserting the large diameter end of the mandrel into the opening in the member, moving the puller and mandrel forwardly to push the large diameter end of the mandrel through the opening and position the insert and split sleeve within the opening, and with the lock ring positioned adjacent the side of the member opposite the puller tube, operating the puller tube to pull the mandrel through the split sleeve and the insert, for radially expanding both the split sleeve and the insert to in that manner radially expand the insert into an interference fit within the opening, and then removing the mandrel and the split sleeve from the insert, leaving the insert in the opening connected to the member.

Inventors: JOHNSON TIMOTHY H, REID LEONARD F, JOHNSON, TIMOTHY, H., REID, LEONARD, F.
Applicants: FATIGUE TECHNOLOGY INC, JOHNSON TIMOTHY H, REID LEONARD F, FATIGUE TECHNOLOGY, INC., JOHNSON, TIMOTHY, H., REID, LEONARD, F.
Application year: 1998
Main classification: F16B37
IPC codes: F16B17, F16B37