Patent Publication Number: US-2022234267-A1

Title: Dual torque and injection molding device

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a divisional application of U.S. Ser. No. 16/275,974, filed Feb. 14, 2019 and titled “DUAL TORQUE AND INJECTION MOLDING DEVICE,” the content of which is incorporated herein in its entirety. 
    
    
     FIELD 
     The present disclosure relates to drivers and methods for installing threaded fasteners, and more specifically to threaded fasteners in electrical applications. 
     BACKGROUND 
     The statements in this section merely provide background information related to the present disclosure and may not constitute prior art. 
     Some components in high voltage electrical systems (e.g., terminals in electric vehicle traction batteries) include threaded fasteners that carry a high voltage (e.g., greater than 300 volts). In some situations, it is beneficial to construct the terminal such that fingers or other objects cannot accidently touch these fasteners. However, in some applications, it can be beneficial for these high voltage fasteners remain accessible to authorized and trained personnel for service, while still inhibiting accidental contact. 
     The present disclosure addresses these issues associated with high voltage threaded fastener installation. 
     SUMMARY 
     This section provides a general summary of the disclosure and is not a comprehensive disclosure of its full scope or all of its features. 
     In one form, a tool for driving a threaded fastener includes a driver head, a motor, and an injector. The driver head includes a spindle rotatable about an axis. A distal end of the spindle defines a plurality of drive surfaces configured to engage mating drive surfaces on the fastener to rotate the fastener about the axis. The driver head defines a fluid passage having an outlet proximate to the distal end of the spindle. The motor is drivingly coupled to the spindle to rotate the spindle about the axis. The injector is coupled to an inlet of the fluid passage and configured to feed a liquid insulator through the fluid passage. In a variety of alternate forms of the present disclosure: the spindle defines a recess configured to receive a tool engagement portion of the fastener, the drive surfaces at least partially defining the recess; the spindle defines the fluid passage and the outlet opens to the recess; the drive surfaces are disposed on walls that extend radially inward from perimeter walls of the recess; the drive surfaces are disposed on at least one protrusion of the distal end of the spindle, the at least one protrusion configured to be received in at least one recess of the fastener; the spindle defines the fluid passage coaxial with the axis; the driver head further comprises a sleeve axially translatable relative to the spindle and disposed coaxially about the spindle, the sleeve at least partially defining a mold cavity that encapsulates a tool engagement portion of the fastener; the sleeve defines the fluid passage; spindle at least partially defines the mold cavity; the sleeve includes a plurality of sleeve members that are radially movable relative to the spindle between a first radial position and a second radial position, wherein when the sleeve members are in the second radial position the sleeve members are closer to the axis than when in the first radial position and the sleeve members cooperate to at least partially define the mold cavity; mold cavity has a perimeter shape that is different than a perimeter shape of the tool engagement portion of the fastener; the drive head further comprises an injection shaft that defines the fluid passage and is axially translatable relative to the spindle, wherein the spindle is disposed coaxially about the injection shaft. 
     In another form, a tool for driving a threaded fastener includes a driver head and a motor. The driver head defines an injection mold cavity and a fluid conduit. The driver head includes a fastener engagement portion configured to engage a tool engagement portion of the fastener. The fastener engagement portion and the mold cavity are coaxially disposed about an axis. An outlet of the fluid conduit is open to the mold cavity. The mold cavity is configured to surround the tool engagement portion of the fastener. The motor is drivingly coupled to the fastener engagement portion to rotate the fastener engagement portion about the axis. In a variety of alternate forms of the present disclosure: the driver head includes a spindle that is rotatable about the axis, wherein a proximal end of the spindle is drivingly coupled to the motor to receive torque therefrom and a distal end of the spindle includes the fastener engagement portion and defines the mold cavity; the driver head includes a spindle and a sleeve, wherein the spindle is rotatable about the axis and the sleeve is coaxially disposed about the spindle, wherein the mold cavity is at least partially defined by the sleeve; the driver head includes a spindle and an injection shaft, wherein the spindle is rotatable about the axis and coaxially disposed about the injection shaft, wherein the injection shaft is axially translatable relative to the spindle. 
     In yet another form, a method of installing a threaded fastener includes aligning a driver head of a tool coaxially with the fastener, tightening the fastener by rotating a spindle of the driver head to engage and rotate a tool engagement portion of the fastener until the fastener is in an installed state, and encapsulating at least the tool engagement portion of the fastener by ejecting a liquid insulator from the driver head onto the installed fastener and allowing the insulator to solidify and form an electrically insulating cap around at least the tool engagement portion of the fastener. In a variety of alternate forms of the present disclosure: the method further includes retracting the spindle axially away from the fastener and positioning an injection shaft proximate to the tool engagement portion of the fastener, the injection shaft being coaxial with the spindle and defining a fluid conduit through which the liquid insulator is ejected; the method further includes retracting the spindle axially away from the fastener and positioning a sleeve of the driver head so that at least the tool engagement portion of the fastener is within a mold cavity that is at least partially defined by the sleeve, wherein the sleeve is movable relative to the spindle and disposed coaxially about the spindle, and wherein the liquid insulator is ejected from the sleeve, the spindle, or both the sleeve and the spindle; the sleeve is defined by a plurality of sleeve members, the method further comprising forming the mold cavity by moving the sleeve members radially inward toward the fastener. 
     Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. 
    
    
     
       DRAWINGS 
       In order that the disclosure may be well understood, there will now be described various forms thereof, given by way of example, reference being made to the accompanying drawings, in which: 
         FIG. 1  is a perspective view of a driver of a first construction in accordance with the teachings of the present disclosure, illustrating an example of a fastener to be installed; 
         FIG. 2  is a bottom view of a spindle of the driver of  FIG. 1 , illustrating a positioning of a head of the fastener of  FIG. 1  in dashed lines; 
         FIG. 3  is a cross-sectional view of the spindle and head of the fastener of  FIG. 2 ; 
         FIG. 4  is a perspective view of the head of the fastener of  FIG. 1  in a fully installed condition; 
         FIG. 5  is a perspective view of a portion of the driver of  FIG. 1 , illustrating optional vent features in accordance with the teachings of the present disclosure; 
         FIG. 6  is a perspective view of a driver of a second construction in accordance with the teachings of the present disclosure, illustrating an example of a fastener to be installed; 
         FIG. 7  is a cross-sectional view of a portion of the driver of  FIG. 6  in a first mode; 
         FIG. 8  is a cross-sectional view of the portion of the driver of  FIG. 6 , illustrated in a second mode; 
         FIG. 9  is a perspective view of the head of the fastener of  FIG. 6  in a fully installed condition; 
         FIG. 10  is a perspective view of a driver of a third construction in accordance with the teachings of the present disclosure, illustrating an example of a fastener to be installed; 
         FIG. 11  is a cross-sectional view of a portion of the driver of  FIG. 10  in a first mode; 
         FIG. 12  is a cross-sectional view of the portion of the driver of  FIG. 10 , illustrated in a second mode; 
         FIG. 13  is a perspective view of the head of the fastener of  FIG. 10  in a fully installed condition; 
         FIG. 14  is a perspective view of a driver of a fourth construction in accordance with the teachings of the present disclosure, illustrating an example of a fastener to be installed; 
         FIG. 15  is a cross-sectional view of a portion of the driver of  FIG. 14  in a first mode; 
         FIG. 16  is a cross-sectional view of the portion of the driver of  FIG. 14 , illustrated in a second mode; 
         FIG. 17  is a perspective view of the head of the fastener of  FIG. 14  in a fully installed condition; 
         FIG. 18  is a perspective view of a driver of a fifth construction in accordance with the teachings of the present disclosure, illustrating an example of a fastener to be installed; 
         FIG. 19  is a cross-sectional view of a portion of the driver of  FIG. 18  in a first mode; 
         FIG. 20  is a cross-sectional view of the portion of the driver of  FIG. 18 , illustrated in a second mode; 
         FIG. 21  is a perspective view of the head of the fastener of  FIG. 18  in a fully installed condition; 
         FIG. 22  is a perspective view of a driver of a sixth construction in accordance with the teachings of the present disclosure, illustrating an example of a fastener to be installed; 
         FIG. 23  is a cross-sectional view of a portion of the driver of  FIG. 22  in a first mode; 
         FIG. 24  is a cross-sectional view of the portion of the driver of  FIG. 22 , illustrated in a second mode; and 
         FIG. 25  is a perspective view of the head of the fastener of  FIG. 22  in a fully installed condition. 
     
    
    
     The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way. 
     DETAILED DESCRIPTION 
     The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features. Examples are provided to fully convey the scope of the disclosure to those who are skilled in the art. Numerous specific details are set forth such as types of specific components, devices, and methods, to provide a thorough understanding of variations of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed and that the examples provided herein, may include alternative embodiments and are not intended to limit the scope of the disclosure. In some examples, well-known processes, well-known device structures, and well-known technologies are not described in detail. 
     Referring to  FIG. 1 , a tool  110  is illustrated positioned above an example fastener  10  and a component  14 . The fastener  10  is a threaded fastener (e.g., a screw, a bolt, or a nut) that is installed on the component  14  by torqueing the fastener relative to the component  14  or relative to a mating part of the fastener (e.g., a nut or bolt). In the example provided, the fastener  10  is a bolt having a head  18  and a shaft  22 . The shaft  22  is received in a bore  26  of the component  14  and either threadably engaged with a nut (not shown) on the opposite side of the component  14  or threads in the bore  26 . In the example provided, the component  14  is a component of a high voltage device, such as a vehicle battery or other part of an electrical system of an electric vehicle (not shown), though other configurations can be used. The fastener  10  can be configured to secure a component that carries electrical current or is at a high voltage (e.g., an electrical terminal  30  for an electrical cable  34 , shown in  FIGS. 18-20 ). As such, the component  14  can be configured such that the fastener  10  can become electrically charged when in operation on the vehicle (not shown). 
     The tool  110  includes a driver head  114  and a motor  118 . The tool  110  can also include an injection molding supply configured to provide an electrically insulating material in liquid form to the driver head  114 . In the example provided, the electrically insulating material is supplied in liquid form by an injector  122  via a conduit  126 , though other configurations can be used. The injector  122  can be any suitable device configured to convey the liquid material to the driver head  114 , such as a pump for example. The injector  122  can be mounted for movement with the driver head  114  or can be remote from the driver head  114 . In one configuration, the injector  122  can also be configured to receive the electrically insulating material in solid form and convert (e.g., melt) it to liquid form. One non-limiting example of such an electrically insulating material can be an electrically insulating polymer, though other materials can be used. 
     The driver head  114  includes a spindle  130  that has a distal end  134  generally configured to impart torque to the fastener  10 . The motor  118  is drivingly coupled to the spindle  130  (e.g., near an opposite end of the spindle  130 ) and configured to rotate the spindle  130  about the spindle&#39;s rotational axis  138 . In one configuration, the driver head  114  can be coupled to a robotic arm (not shown). In another configuration, the driver head  114  can be coupled to a handle (not shown) to be used as a hand tool. Other configurations can be used, such as mounted to another type of machine (not shown) configured to move the driver head  114  relative to the component  14  or vice versa. 
     Referring to  FIGS. 2 and 3 , the distal end  134  of the spindle  130  defines a mold cavity  142  and includes a plurality of engagement members  146  that extend radially inward from the perimeter of the mold cavity  142 . In the example provided, the mold cavity  142  is a hexagonal shape and the engagement members  146  are protruding walls that extend radially inward from approximately the mid-sections of each hexagonal wall of the mold cavity  142 , though other configurations can be used. In one alternative configuration, not specifically shown, the mold cavity  142  can be round and the engagement members  146  can extend radially inward from the cylindrical wall. 
     Returning to the example provided, the engagement members  146  have drive surfaces  150  configured to contact tool engagement surfaces  154  of the fastener  10 . In the example provided, the head  18  of the fastener  10  is a hexagonal shape and the tool engagement surfaces  154  are the perimeter faces of the head  18  that make up the hexagonal shape, though other configurations can be used. In one alternative construction, not specifically shown, the radially extending engagement members  146  can be replaced with one or more engagement member (not shown) that extends axially down into the mold cavity  142  to engage one or more recesses in an axial end of the fastener (not specifically shown). 
     Returning to the example provided, the spindle  130  also defines a fluid passageway  158  having an outlet open to the mold cavity  142  and an inlet in fluid communication with the injector  122  to receive the liquid electrically insulating material therefrom. The spindle may also optionally define one or more vents to allow air to be displaced from the mold cavity  142  when the liquid material is injected into the mold cavity  142 . In the example shown in  FIG. 3 , the spindle  130  lacks such vents, but the tolerances of the distal end  134  of the spindle  130  and the component  14  can be such that air can escape between the distal end  134  and the component  14 , or the distal end  134  can be held in a position such that a slight air gap is permitted between the distal end  134  and the component  14 . Referring to  FIG. 5 , one example configuration of the optional vents is illustrated in which the distal end  134  of the spindle  130  defines one or more vent channels  162  extending radially through the spindle  130  into the mold cavity  142 . 
     In operation, the spindle  130  is lowered onto the fastener  10  so that the head  18  of the fastener  10  is received in the mold cavity  142 , as shown in  FIG. 3 . The motor  118  is then operated to rotate the spindle  130  and tighten the fastener  10  to a desired torque. With the spindle  130  remaining in the position shown in  FIG. 3 , the injector  122  is operated to provide liquid material through the fluid passageway  158  and into the mold cavity  142 . The liquid material fills the mold cavity  142  and is allowed to solidify around the head  18 . The spindle  130  can remain in this position until the material is solidified sufficiently to retract the spindle  130 . 
     Referring to  FIG. 4 , the solidified electrically insulating material forms an electrically insulating cap  166  over the head  18  of the fastener  10 . In the example provided, the cap  166  includes a plurality of gaps  170  as a result of the engagement members  146 . However, these gaps  170  are sufficiently small enough to inhibit unintentional contact (e.g., by a person&#39;s fingers) with the fastener  10 . 
     The shape of the mold cavity  142  dictates the shape of the cap  166  such that the mold cavity  142  shape can control the ability to loosen the fastener  10  with standard tools (e.g., hexagonal shape) proprietary tools (not specifically shown), or to make it more difficult for a user to loosen the fastener  10  without first removing the cap  166  (e.g., round shape). Additionally, the shape of the mold cavity  142  can hide or disguise the fastener from being recognized as a removable or serviceable part. 
     Referring to  FIG. 6 , a portion of a tool  210  of a second construction is illustrated positioned above the example fastener  10  and the component  14 . The tool  210  is similar to the tool  110  ( FIGS. 1-5 ), except as otherwise shown or described herein. The tool  210  includes a driver head  214  and the motor  118  ( FIG. 1 ). The tool  210  can also include the injector  122  ( FIG. 1 ). The driver head  214  is similar to the driver head  114  ( FIGS. 1-5 ) except as otherwise shown or described herein. In the example provided, the driver head  214  includes a spindle  218  and a sleeve  222 . 
     The spindle  218  has a distal end  226  generally configured to impart torque to the fastener  10 . The motor  118  is drivingly coupled to the spindle  218  to rotate the spindle  218  about the rotational axis  230 . With additional reference to  FIG. 7 , the distal end  226  of the spindle  218  includes a plurality of drive surfaces  234  configured to engage the tool engagement surfaces  154  of the fastener  10 . In the example provided, the drive surfaces  234  define a hexagonal recess  238  open through the distal end  226  of the spindle  218 , though other mating configurations can be used. 
     In one alternative construction, not specifically shown, the recess  238  can be replaced with one or more engagement members (not shown) that extend axially down to define the drive surfaces to engage one or more recesses in an axial end of a fastener (not specifically shown). 
     Referring to  FIGS. 7 and 8 , the sleeve  222  is disposed coaxially about the spindle  218 . The spindle  218  is axially slidable relative to the sleeve  222  between a driving position (e.g., shown in  FIG. 7 ) and a molding position (e.g., shown in  FIG. 8 ). In the driving position, the distal end  226  of the spindle  218  can engage the fastener  10 . In the example provided, the distal end  226  is extended beyond a distal end  242  of the sleeve  222 . Alternatively, the distal ends  226 ,  242  can be flush while still permitting engagement of the fastener  10 . In the molding position, the distal end  226  of the spindle  218  is retracted into the sleeve  222  so that the sleeve  222  and the distal end  226  of the spindle  218  define a mold cavity  246  configured to encapsulate the head  18  of the fastener  10 . In the example provided, the mold cavity  246  is generally cylindrical except for the portion defined by the recess  238 , as shown in  FIGS. 8 and 9 , though other shapes can be used. In the example provided, the spindle  218  is configured to rotate relative to the sleeve  222 , though the sleeve  222  could be configured to rotate with the spindle  218 . 
     The sleeve  222  defines one or more fluid passageways. In the example provided, the sleeve  222  defines a first fluid passageway  250  and a second fluid passageway  254  and each is coupled to the injector  122  to receive the liquid material therefrom. Each fluid passageway  250 ,  254  has an outlet open into the mold cavity  246  when the spindle  218  is in the molding position. When the spindle  218  is in the driving position, an outer surface  258  of the spindle  218  can close off and seal the outlets of the fluid passageways  250 ,  254 . 
     In the example shown, the spindle  218  and the sleeve  222  lack vents, but the tolerances between the spindle  218  and the sleeve  222  and/or between the distal end  242  of the sleeve  222  and the component  14  can be such that air can escape therebetween, or the sleeve  222  can be held in a position such that a slight air gap is permitted between the distal end  242  of the sleeve  222  and the component  14 . In an alternative construction, not specifically shown, the sleeve  222  can include vent channels similar to those illustrated in  FIG. 5  extending radially through the sleeve  222  into the mold cavity  246 . In another alternative configuration, the first fluid passageway  250  is coupled to the injector  122  and the second fluid passageway  254  is open to the exterior of the tool  210  to act as a vent. 
     In operation, the spindle  218  is positioned in the driving position and lowered onto the fastener  10  so that the head  18  is engaged by the spindle  218 , as shown in  FIG. 7 . The motor  118  ( FIG. 1 ) is then operated to rotate the spindle  218  and tighten the fastener  10 . The spindle  218  is then moved to the molding position with the head  18  encapsulated by the mold cavity  246 , as shown in  FIG. 8 . The injector  122  ( FIG. 1 ) then provides liquid material through the passageways  250 ,  254  and into the mold cavity  246 . The liquid material fills the mold cavity  246  and is allowed to solidify around the head  18 . The driver head  214  can remain in this position until the material solidifies sufficiently to retract the driver head  214 , as shown in  FIG. 9 . Referring to  FIG. 9 , the solidified electrically insulating material forms an electronically insulating cap  262  over the head  18  of the fastener  10 . 
     Referring to  FIG. 10 , a portion of a tool  310  of a third construction is illustrated positioned above the example fastener  10  and the component  14 . The tool  310  is similar to the tool  210  ( FIGS. 6-9 ), except as otherwise shown or described herein. The tool  310  includes a driver head  314  and the motor  118  ( FIG. 1 ). The tool  310  can also include the injector  122  ( FIG. 1 ). The driver head  314  is similar to the driver head  214  ( FIGS. 6-9 ) except as otherwise shown or described herein. The driver head  314  includes a spindle  318  and a sleeve  322 . 
     The spindle  318  has a distal end  326  generally configured to impart torque to the fastener  10 . The motor  118  ( FIG. 1 ) is drivingly coupled to the spindle  318  to rotate the spindle  318  about the rotational axis  330 . With additional reference to  FIG. 11 , the distal end  326  of the spindle  318  includes a plurality of drive surfaces  334  configured to engage the tool engagement surfaces  154  of the fastener  10 . In the example provided, the drive surfaces  334  define a hexagonal recess  338  open through the distal end  326  of the spindle  318 , though other mating configurations can be used. The spindle  318  also defines a fluid passageway  342  that has an inlet coupled to the injector  122  and an outlet open into the recess  338 . 
     Referring to  FIGS. 11 and 12 , the sleeve  322  is disposed coaxially about the spindle  318 . The spindle  318  is axially slidable relative to the sleeve  322  between a driving position (e.g., shown in  FIG. 11 ) and a molding position (e.g., shown in  FIG. 12 ). In the driving position, the distal end  326  is extended beyond or flush with a distal end  346  of the sleeve  322  to engage the fastener  10 . In the molding position, the distal end  326  of the spindle  318  is retracted into the sleeve  322  so that the sleeve  322  and the distal end  326  of the spindle  318  define a mold cavity  350  that can encapsulate the head  18  of the fastener  10 . 
     In the example provided, the mold cavity  350  is generally cylindrical except for the portion defined by the recess  338 , as shown in  FIGS. 12 and 13 , though other shapes can be used. Thus, in the example provided, the recess  338 , forms part of the mold cavity  350  and the fluid passageway  342  is open to the mold cavity  350 . In the example provided, the spindle  318  is configured to rotate relative to the sleeve  322 , though the sleeve  322  could be configured to rotate with the spindle  318 . 
     In an alternative construction, not specifically shown, the recess  338  can be replaced with one or more engagement member (not shown) that extends axially down to define the drive surfaces to engage one or more recesses in an axial end of a fastener (not specifically shown). 
     In the example shown, the spindle  318  and sleeve  322  lack vents, but the tolerances of the parts can provide sufficient venting as described above. In an alternative construction, not shown, the sleeve  322  can include vent channels (e.g., similar to those shown in  FIG. 5 ) extending radially through the sleeve  322  into the mold cavity  350 , or a vent passageway can be defined by the spindle  318  and/or the sleeve  322 . 
     In operation, the spindle  318  is positioned in the driving position and lowered onto the fastener  10  to engage the head  18 , as shown in  FIG. 11 . The motor  118  ( FIG. 1 ) is then operated to rotate the spindle  318  and tighten the fastener  10 . The spindle  318  is then moved to the molding position with the head  18  encapsulated by the mold cavity  350 , as shown in  FIG. 12 . The injector  122  ( FIG. 1 ) then provides the liquid material through the passageway  342  and into the mold cavity  350 . The liquid material fills the mold cavity  350  and is allowed to solidify around the head  18 . The driver head  314  can remain in this position until the liquid material solidifies sufficiently to retract the driver head  314 , as shown in  FIG. 13 . Referring to  FIG. 13 , the solidified electrically insulating material forms an electronically insulating cap  354  over the head  18  of the fastener  10 . 
     Referring to  FIG. 14 , a portion of a tool  410  of a fourth construction is illustrated positioned above the example fastener  10  and the component  14 . The tool  410  is similar to the tool  210  ( FIGS. 6-9 ), except as otherwise shown or described herein. The tool  410  includes a driver head  414  and the motor  118  ( FIG. 1 ). The tool  410  can also include the injector  122  ( FIG. 1 ). The driver head  414  is similar to the driver head  214  ( FIGS. 6-9 ) except as otherwise shown or described herein. The driver head  414  includes a spindle  418  and a sleeve  422 . 
     The spindle  418  has a distal end  426  generally configured to impart torque to the fastener  10 . The motor  118  ( FIG. 1 ) is drivingly coupled to the spindle  418  to rotate the spindle  418  about the rotational axis  430 . With additional reference to  FIG. 15 , the distal end  426  of the spindle  418  includes a plurality of drive surfaces  434  configured to engage the tool engagement surfaces  154  of the fastener  10 . In the example provided, the drive surfaces  434  define a hexagonal recess  438  open through the distal end  426  of the spindle  418 , though other mating configurations can be used. 
     In an alternative construction, not specifically shown, the recess  438  can be replaced with one or more engagement members (not shown) that extend axially down to define the drive surfaces to engage one or more recesses in an axial end of the fastener (not specifically shown). 
     Referring to  FIGS. 15 and 16 , the sleeve  422  is disposed coaxially about the spindle  418  and is formed from a plurality of sleeve sections. In the example provided, the sleeve  422  is formed of two sleeve sections  442 ,  446  that form halves of the sleeve  422 , though the sleeve  422  could include more than two sections. The sleeve sections  442 ,  446  are configured to move radially relative to the spindle  418  and the spindle  418  is axially movable relative to the sleeve  422  such that the driver head  414  can be changed between a driving position (e.g., shown in  FIG. 15 ) and a molding position (e.g., shown in  FIG. 16 ). 
     In the driving position, the sleeve sections  442 ,  446  are more radially apart than when in the molding position. In the driving position, the distal end  426  of the spindle  418  is flush with or extends beyond a distal end  450  of the sleeve  422  to engage the fastener  10 . 
     In the molding position, the distal end  426  of the spindle  418  is retracted up into the sleeve  422  and the sleeve sections  442 ,  446  are moved radially inward so that the sleeve sections  442 ,  446  contact each other and define a mold cavity  454  configured to encapsulate the head  18  of the fastener  10 . In the example provided, no part of the spindle  418  defines the mold cavity  454 . The mold cavity  454  can be generally cylindrical, as shown in  FIGS. 16 and 17 , though other shapes can be used. In the example provided, the spindle  418  is configured to rotate relative to the sleeve  422 , though the sleeve  422  could be configured to rotate with the spindle  418 . 
     The sleeve  422  defines one or more fluid passageways. In the example provided, the sleeve section  442  defines a first fluid passageway  458  and the sleeve section  446  defines a second fluid passageway  462  and each fluid passageway  458 ,  462  is coupled to the injector  122  to receive the liquid material therefrom. Each fluid passageway  458 ,  462  has an outlet open into the mold cavity  454  when the driver head  414  is in the molding position. 
     In the example shown, the sleeve  422  lack vents, but the tolerances of the parts can provide sufficient venting as described above. In an alternative construction, not specifically shown, the sleeve  422  can include vent channels (e.g., similar to those shown in  FIG. 5 ) extending radially through the sleeve  422  into the mold cavity  454 , or a vent passageway can be defined by the sleeve  422 . 
     In operation, the driver head  414  is positioned in the driving position and lowered so the spindle  418  engages the fastener  10 , as shown in  FIG. 15 . The motor  118  ( FIG. 1 ) is then operated to rotate the spindle  418  and tighten the fastener  10 . The driver head  414  is then moved to the molding position with the head  18  encapsulated by the mold cavity  454 , as shown in  FIG. 16 . The injector  122  ( FIG. 1 ) then provides liquid material through the passageways  458 ,  462  and into the mold cavity  454 . The liquid material fills the mold cavity  454  and is allowed to solidify around the head  18 . The driver head  414  can remain in this position until the material solidifies sufficiently to retract the driver head  414 , as shown in  FIG. 17 . Referring to  FIG. 17 , the solidified electrically insulating material forms an electronically insulating cap  466  over the head  18  of the fastener  10 . 
     Referring to  FIG. 18 , a portion of a tool  510  of a fifth construction is illustrated positioned above the example fastener  10  and a component  38 . The component  38  is one example of a different configuration of the component  14  ( FIG. 1 ). The component  38  defines a terminal channel  42  recessed from an outer surface  46  of the component  38 . The electrical cable  34  extends along the terminal channel  42  and the electrical terminal  30  is coupled to the end of the cable  34  for electrical communication therewith. The fastener  10  is configured to affix the terminal  30  to the component  38 . 
     The tool  510  is similar to the tool  210  ( FIGS. 6-9 ), except as otherwise shown or described herein. The tool  510  includes a driver head  514  and the motor  118  ( FIG. 1 ). The tool  510  can also include the injector  122  ( FIG. 1 ). The driver head  514  is similar to the driver head  214  ( FIGS. 6-9 ) except as otherwise shown or described herein. In the example provided, the driver head  514  includes a spindle  518  and an injection shaft  522 . 
     The spindle  518  has a distal end  526  generally configured to impart torque to the fastener  10 . The motor  118  ( FIG. 1 ) is drivingly coupled to the spindle  518  to rotate the spindle  518  about the rotational axis  530 . With additional reference to  FIG. 19 , the distal end  526  of the spindle  518  includes a plurality of drive surfaces  534  configured to engage the tool engagement surfaces  154  of the fastener  10 . In the example provided, the drive surfaces  534  define a hexagonal recess  538  open through the distal end  526  of the spindle  518 , though other mating configurations can be used. 
     In an alternative construction, not specifically shown, the recess  538  can be replaced with one or more engagement members (not shown) that extend axially down to define the drive surfaces to engage one or more recesses in an axial end of the fastener (not specifically shown). 
     Referring to  FIGS. 19 and 20 , the spindle  518  is disposed coaxially about the injection shaft  522 . The injection shaft  522  is axially slidable relative to the spindle  518  between a driving position (e.g., shown in  FIG. 19 ) and a molding position (e.g., shown in  FIG. 20 ). In the driving position, the distal end  526  of the spindle  518  is configured to engage the fastener  10  and the injection shaft  522  is retracted up into the spindle  518 . In the molding position, a distal end  542  of the injection shaft  522  is extended to be either flush with or extended beyond the distal end  526  of the spindle  518 . In the example provided, the spindle  518  is configured to rotate relative to the injection shaft  522 , though in an alternative configuration, the injection shaft  522  could rotate with the spindle  518 . 
     The injection shaft  522  defines one or more fluid passageways. In the example provided, the injection shaft  522  defines a central fluid passageway  546  that is coupled to the injector  122  to receive the liquid material therefrom. The fluid passageway  546  has an outlet open through the distal end  542  of the injection shaft  522 . 
     In operation, the spindle  518  is positioned in the driving position and lowered to engage the fastener  10 , as shown in  FIG. 19 . The motor  118  ( FIG. 1 ) is then operated to rotate the spindle  518  and tighten the fastener  10 . The spindle  518  is then moved to the molding position with the head  18  directly below the injection shaft  522 , as shown in  FIG. 20 . The injector  122  ( FIG. 1 ) then provides liquid material through the passageway  546  and onto the fastener head  18  and terminal  30  within the terminal channel  42 . The liquid material can fill the terminal channel  42  around the fastener  10  and the terminal  30  and is allowed to solidify therein to form an electrically insulating cap  550  over the head  18  of the fastener  10 , as shown in  FIG. 21 . 
     Referring to  FIG. 22 , a portion of a tool  610  of a sixth construction is illustrated positioned above an example fastener  50 . The fastener  50  is similar to the fastener  10  ( FIG. 1 ) except that a head  54  of the fastener  50  specifically includes internal tool engagement surfaces  58  recessed within the axial end of the head  54 . The tool  610  is similar to the tool  310  ( FIGS. 10-13 ), except as otherwise shown or described herein. The tool  610  includes a driver head  614  and the motor  118  ( FIG. 1 ). The tool  610  can also include the injector  122  ( FIG. 1 ). The driver head  614  is similar to the driver head  314  ( FIGS. 10-13 ) except as otherwise shown or described herein. In the example provided, the driver head  614  includes a spindle  618 , but lacks the sleeve  322  ( FIGS. 10-13 ). 
     The spindle  618  has a distal end  622  configured to impart torque to the fastener  50 . The motor  118  ( FIG. 1 ) is drivingly coupled to the spindle  618  to rotate the spindle  618  about the rotational axis  626 . With reference to  FIGS. 22 and 23 , the distal end  622  of the spindle  618  includes a plurality of protrusions having drive surfaces  630  configured to be received into the axial end of the head  54  to engage the tool engagement surfaces  58  of the fastener  50 . In the example provided, the drive surfaces  630  define a cross or plus-shaped protrusion, though other mating configurations can be used. The spindle  618  also defines a fluid passageway  634  that has an inlet coupled to the injector  122  and an outlet open through the distal end  622  of the spindle. In the example provided, the fluid passageway is coaxial with the axis  626 . 
     In operation, the spindle  618  is positioned in a driving position in which the spindle  618  is lowered onto the fastener  50  so that the head  54  is engaged by the spindle  618 , as shown in  FIG. 23 . The motor  118  ( FIG. 1 ) is then operated to rotate the spindle  618  and tighten the fastener  50 . The spindle  618  is then moved to a molding position above the head  54 , as shown in  FIG. 24 . The injector  122  ( FIG. 1 ) can be operated to provide liquid material through the passageway  634  and onto the head  54  while the spindle  618  is retracting or after reaching a predetermined distance from the head  54 . The liquid material completely covers the head  54  and is allowed to solidify around the head  54 , as shown in  FIG. 25 . Referring to  FIG. 25 , the solidified electrically insulating material forms an electronically insulating cap  638  over the head  54  of the fastener  50 . 
     In an alternative configuration, not specifically shown, the driver head  614  can include a sleeve similar to the sleeve  322  ( FIGS. 10-13 ) disposed coaxially about the spindle  618 . Operation of such a configuration would be similar to that described above with reference to  FIGS. 10-13 . 
     As used herein, the phrase at least one of A, B, and C should be construed to mean a logical (A OR B OR C), using a non-exclusive logical OR, and should not be construed to mean “at least one of A, at least one of B, and at least one of C. 
     Unless otherwise expressly indicated, all numerical values indicating mechanical/thermal properties, compositional percentages, dimensions and/or tolerances, or other characteristics are to be understood as modified by the word “about” or “approximately” in describing the scope of the present disclosure. This modification is desired for various reasons including industrial practice, manufacturing technology, and testing capability. 
     The terminology used herein is for the purpose of describing particular example forms only and is not intended to be limiting. The singular forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed. 
     The description of the disclosure is merely exemplary in nature and, thus, examples that do not depart from the substance of the disclosure are intended to be within the scope of the disclosure. Such examples are not to be regarded as a departure from the spirit and scope of the disclosure. The broad teachings of the disclosure can be implemented in a variety of forms. Therefore, while this disclosure includes particular examples, the true scope of the disclosure should not be so limited since other modifications will become apparent upon a study of the drawings, the specification, and the following claims.