Patent ID: 12247609

DETAILED DESCRIPTION

The various examples of fastener systems and methods for joining multiple substrates of a workpiece disclosed herein provide techniques for pre-installing a nut member of the fastener system on a blind side of the workpiece and one-sided installation of other members of the fastener system from a working side of the workpiece. The workpiece, for example, may include one or more composite material substrates and may be used for aerospace construction.

Referring generally toFIGS.1,2A-B,3,4A-C and5-7, by way of examples, the present disclosure is directed to a fastener system100for joining multiple substrates102of a workpiece104. The workpiece104has a working side106and a blind side108.FIGS.1and5-7disclose examples of the fastener system100.FIG.2Ashows a side view of an example of a sleeve member118of the fastener system100.FIG.2Bshows a distal end view of the sleeve member ofFIG.2A.FIG.3shows an example of a nut member110of the fastener system100.FIGS.4A-Cshow examples of joining bores116in the workpiece104ofFIG.1with a countersunk portion402, a counterbored portion404and a cylindrical portion406.

With reference again to1,2A-B,3,4A-C and5-7, in one or more examples, a fastener system100for joining multiple substrates102of a workpiece104includes a nut member110, a sleeve member118and a bolt member120. The workpiece104has a working side106and a blind side108. The nut member110includes a nut bore112with internal threads114. The nut member110configured for placement of the nut bore112over a joining bore116through the multiple substrates102on the blind side108of the workpiece104. The sleeve member118includes an outer sleeve surface202with a lubricious coating204. The sleeve member118configured for insertion in the joining bore116through the multiple substrates102from the working side106of the workpiece104. The bolt member120includes a head portion122, a threaded portion124and a shank portion126extending between the head portion122and the threaded portion124. The bolt member120configured for insertion in a central bore206of the sleeve member118. The threaded portion124configured for threaded engagement with the internal threads114of the nut member110. As the bolt member120becomes fully engaged with the nut member110, the shank portion126of the bolt member120is configured to cause radial expansion of the sleeve member118and the sleeve member118is configured to provide an interference fit502within the joining bore116through the multiple substrates102.

In another example of the fastener system100, the multiple substrates102include at least one composite material substrate128. In yet another example of the fastener system100, the nut member110is configured to be secured to the blind side108of the workpiece104. In a further example, the nut member110is configured to be secured to the blind side108of the workpiece104using mechanical fasteners, swagging or any other suitable fastening hardware/technique in any suitable combination.

In still another example of the fastener system100, the nut member110includes a nut plate assembly302with a nut304and a flange plate306captively retaining the nut304. The nut304includes the nut bore112. The flange plate306configured to be secured to the blind side108of the workpiece104with the nut bore112over the joining bore116through the multiple substrates102. In a further example, the nut304captively retained by the flange plate306is spaced from a mounting surface308of the flange plate306. In this example, the flange plate306includes a counterbore310into the mounting surface308in relative alignment with the nut bore112of the nut304and the joining bore116of the multiple substrates102. The counterbore310configured to provide space for a distal end208of the sleeve member118protruding from the joining bore116at the blind side108of the workpiece104as the bolt member120becomes fully engaged with the nut member110.

In still yet another example, the fastener system100also includes a cap sealant member130with a dome132and a cap flange134. The cap sealant member130configured for placement over the nut member110. The cap flange134configured to secure the cap sealant member130to the blind side108of the workpiece104.

In another example of the fastener system100, the sleeve member118includes a malleable metallic material. In a further example, the malleable metallic material includes tin, a tin alloy, copper, a copper alloy, aluminum, an aluminum alloy, silver, a silver alloy, gold, a gold alloy or any other suitable malleable metallic in any suitable combination.

In yet another example of the fastener system100, the lubricious coating204includes indium, an indium alloy, tin, a tin alloy, bismuth, a bismuth alloy, aluminum, an aluminum alloy or any other suitable lubricious coating in any suitable combination. In still another example of the fastener system100, the lubricious coating204on the outer sleeve surface202includes conductive features configured to provide electromagnetic energy protection to the workpiece104as the bolt member120becomes fully engaged with the nut member110. In still yet another example of the fastener system100, the outer sleeve surface202is coated with a conductive coating210to provide electromagnetic energy protection to the workpiece104as the bolt member120becomes fully engaged with the nut member110. In a further example, the conductive coating210includes indium, an indium alloy, tin, a tin alloy, lead, a lead alloy or any other suitable conductive coating in any suitable combination.

In another example of the fastener system100, the sleeve member118also includes an elongated sleeve body212and a sleeve flange216. The elongated sleeve body212defining the central bore206. The elongated sleeve body212includes the outer sleeve surface202, a proximal end214relating to the working side106of the workpiece104and a distal end208relating to the blind side108of the workpiece104. The sleeve flange216disposed at the proximal end214of the elongated sleeve body212. The sleeve flange216configured to limit further insertion of the sleeve member118into the joining bore116through the multiple substrates102.

In yet another example of the fastener system100, the bolt member120includes a metallic material. In a further example, the metallic material includes a stainless steel, titanium, a titanium alloy, a cobalt-chromium alloy, a nickel-titanium alloy or any other suitable metallic material in any suitable combination. In still another example of the fastener system100, the head portion122of the bolt member120includes a torquing feature136. In a further example, the torquing feature136is configured to facilitate rotation of the bolt member120using a hex key torquing tool, a cross-tip driver torquing tool, a flat tip driver torquing tool, a hex socket torquing tool or any other suitable torquing tool. In still yet another example of the fastener system100, the head portion122of the bolt member120includes a protruding head, a flush head, a countersunk head, a raised head, a recessed hexagon socket head, a recessed cross-tip head, a recessed flat tip head, a hexagon head or any other suitable type of head. In another example of the fastener system100, at the working side106of the workpiece104, the joining bore116through the multiple substrates102includes a countersunk portion402, a counterbored portion404, a cylindrical portion406or any other suitable geometry at the working side106compatible with the head portion122of the bolt member120.

In yet another example of the fastener system100, the sleeve member118also includes an inner sleeve surface218and the shank portion126of the bolt member120includes an outer shank surface138. In this example, at least one of the inner sleeve surface218and the outer shank surface138is coated with the lubricious coating204.

In still another example of the fastener system100, an outer shank diameter for the shank portion126of the bolt member120is substantially greater than an inner sleeve diameter for the sleeve member118. In a further example, the outer shank diameter is substantially greater than the inner sleeve diameter by approximately 0.0005 inches, approximately 0.0010 inches, approximately 0.0015 inches, approximately 0.0020 inches, approximately 0.0025 inches or any other suitable difference measurement resulting in substantial expansion of the sleeve member118. In another further example, the outer shank diameter is substantially greater than the inner sleeve diameter by approximately 0.2 percent, approximately 0.4 percent, approximately 0.6 percent, approximately 0.8 percent, approximately 1.0 percent or any other suitable percentage resulting in substantial expansion of the sleeve member118.

In still yet another example of the fastener system100, the sleeve member118also includes a cylindrical sleeve body220defining the central bore206. The cylindrical sleeve body220includes the outer sleeve surface202, an inner sleeve surface218facing the central bore206, a proximal end214relating to the working side106of the workpiece104and a distal end208relating to the blind side108of the workpiece104. In a further example, the shank portion126of the bolt member120includes a cylindrical shank body140. The cylindrical shank body140includes an outer shank surface138configured to face the inner sleeve surface218of the cylindrical sleeve body220as the bolt member120is inserted into the central bore206and becomes engaged with the nut member110.

In an even further example, an outer shank diameter for the cylindrical shank body140is substantially greater than an inner sleeve diameter for the cylindrical sleeve body220. In an even yet further example, the outer shank diameter is substantially greater than the inner sleeve diameter by approximately 0.0005 inches, approximately 0.0010 inches, approximately 0.0015 inches, approximately 0.0020 inches, approximately 0.0025 inches or any other suitable difference measurement resulting in substantial expansion of the sleeve member118. In another even further example, the outer shank diameter is substantially greater than the inner sleeve diameter by approximately 0.2 percent, approximately 0.4 percent, approximately 0.6 percent, approximately 0.8 percent, approximately 1.0 percent or any other suitable percentage resulting in substantial expansion of the sleeve member118.

In another even further example, as the bolt member120becomes fully engaged with the nut member110, the outer sleeve surface202is configured to provide the interference fit502within the joining bore116through the multiple substrates102in conjunction with a corresponding cylindrical shape of the joining bore116.

In another example of the fastener system100, the sleeve member118also includes an elongated sleeve body212defining the central bore206. The elongated sleeve body212includes the outer sleeve surface202, an inner sleeve surface218facing the central bore206, a proximal end214relating to the working side106of the workpiece104and a distal end208relating to the blind side108of the workpiece104. In this example, at least the inner sleeve surface218is tapered from a larger inner sleeve diameter proximate the proximal end214to a smaller inner sleeve diameter proximate the distal end208such that the central bore206includes a frustoconical sleeve bore602.

In a further example, the outer sleeve surface202is cylindrical such that the elongated sleeve body212includes a cylindrical sleeve body220with the frustoconical sleeve bore602. In an even further example, the shank portion126of the bolt member120includes an elongated shank body604with an outer shank surface138configured to face the inner sleeve surface218as the bolt member120is inserted into the frustoconical sleeve bore602and becomes engaged with the nut member110. In this example, the elongated shank body604is tapered from a larger outer shank diameter proximate the head portion122of the bolt member120to a smaller outer shank diameter proximate the threaded portion124of the bolt member120such that the elongated shank body604includes a frustoconical shank body606.

In an even yet further example, outer shank diameters for the frustoconical shank body606are substantially greater than corresponding inner sleeve diameters that define the frustoconical sleeve bore602. In an even still further example, the outer shank diameters are substantially greater than the corresponding inner sleeve diameters by approximately 0.0005 inches, approximately 0.0010 inches, approximately 0.0015 inches, approximately 0.0020 inches, approximately 0.0025 inches or any other suitable difference measurement resulting in substantial expansion of the sleeve member118. In another even still further example, the outer shank diameters are substantially greater than the corresponding inner sleeve diameters by at least one of approximately 0.2 percent, approximately 0.4 percent, approximately 0.6 percent, approximately 0.8 percent, approximately 1.0 percent or any other suitable percentage resulting in substantial expansion of the sleeve member118.

In another even yet further example, as the bolt member120becomes fully engaged with the nut member110, the outer sleeve surface202is configured to provide the interference fit608within the joining bore116through the multiple substrates102in conjunction with a corresponding cylindrical shape of the joining bore116.

In another further example, the outer sleeve surface202is tapered from a larger outer sleeve diameter proximate the proximal end214to a smaller outer sleeve diameter proximate the distal end208such that the elongated sleeve body212includes a frustoconical sleeve body702. In an even further example, the shank portion126of the bolt member120includes an elongated shank body604with an outer shank surface138configured to face the inner sleeve surface218as the bolt member120is inserted into the frustoconical sleeve bore602and becomes engaged with the nut member110. In this example, the elongated shank body604is tapered from a larger outer shank diameter proximate the head portion122of the bolt member120to a smaller outer shank diameter proximate the threaded portion124of the bolt member120such that the elongated shank body604includes a frustoconical shank body606.

In an even yet further example, outer shank diameters for the frustoconical shank body606are substantially greater than corresponding inner sleeve diameters that define the frustoconical sleeve bore602. In an even still further example, the outer shank diameters are substantially greater than the corresponding inner sleeve diameters by approximately 0.0005 inches, approximately 0.0010 inches, approximately 0.0015 inches, approximately 0.0020 inches, approximately 0.0025 inches or any other suitable difference measurement resulting in substantial expansion of the sleeve member118. In another even still further example, the outer shank diameters are substantially greater than the corresponding inner sleeve diameters by approximately 0.2 percent, approximately 0.4 percent, approximately 0.6 percent, approximately 0.8 percent, approximately 1.0 percent or any other suitable percentage resulting in substantial expansion of the sleeve member118.

In another even yet further example, as the bolt member120becomes fully engaged with the nut member110, the frustoconical shank body606is configured to cause radial expansion of the frustoconical sleeve body702in conjunction with the frustoconical sleeve bore602of the frustoconical sleeve body702and the frustoconical sleeve body702is configured to provide the interference fit704within the joining bore116through the multiple substrates102in conjunction with a corresponding frustoconical shape of the joining bore116.

Referring generally toFIGS.1,2A-B,3and5-17, by way of examples, the present disclosure is directed to methods800,1100,1400for joining multiple substrates102of a workpiece104. The workpiece104has a working side106and a blind side108.FIGS.1and5-7disclose examples of the fastener system100.FIG.2Ashows a side view of an example of a sleeve member118of the fastener system100.FIG.2Bshows a distal end view of the sleeve member ofFIG.2A.FIG.3shows an example of a nut member110of the fastener system100.FIGS.8-10,12,13and15-17disclose various examples of the method800.FIGS.8and11disclose various examples of the method1100.FIGS.8and14disclose various examples of the method1400.

With reference again toFIGS.1,2A-B,3,5-10,12,13and15-17, in one or more examples, a method800(seeFIG.8) for joining multiple substrates102of a workpiece104with a working side106and a blind side108includes securing802a nut member110over a joining bore116through the multiple substrates102on the blind side108of the workpiece104. The nut member110includes a nut bore112with internal threads114. At804, a sleeve member118is inserted in the joining bore116through the multiple substrates102from the working side106of the workpiece104. The sleeve member118includes an outer sleeve surface202with a lubricious coating204. At806, a bolt member120is inserted in a central bore206of the sleeve member118until a distal end of the bolt member120contacts the nut member110. The bolt member120includes a head portion122at a proximal end, a threaded portion124at the distal end and a shank portion (126) extending between the head portion122and the threaded portion124. At808, the bolt member120is rotated to engage the threaded portion124with the internal threads114of the nut member110. At810, the sleeve member118is radially expanded within the joining bore116through the multiple substrates102as the bolt member120becomes fully engaged with the nut member110. At812, an interference fit502is provided for the sleeve member118within the joining bore116through the multiple substrates102in response to radial expansion of the sleeve member118as the bolt member120becomes fully engaged with the nut member110.

In another example of the method800, the securing802the nut member110includes securing902(seeFIG.9) the nut member110to the blind side108of the workpiece104using mechanical fasteners, swagging or any other suitable fastening hardware/technique in any suitable combination.

In yet another example of the method800, the nut member110also includes a nut plate assembly302. In this example, the securing802the nut member110includes captively retaining1002(seeFIG.10) a nut304of the nut plate assembly302in a flange plate306of the nut plate assembly302. At1004, the flange plate306is secured to the blind side108of the workpiece104with the nut bore112over the joining bore116through the multiple substrates102. In a further example, the securing802the nut member110also includes spacing1006the nut304of the nut plate assembly302from a mounting surface308of the flange plate306. At1008, a counterbore310is provided in the mounting surface308of the flange plate306in relative alignment with the nut bore112of the nut304and the joining bore116of the multiple substrates102. In this example, the counterbore310provides space for a distal end208of the sleeve member118protruding from the joining bore116at the blind side108of the workpiece104as the bolt member120becomes fully engaged with the nut member110.

With reference again toFIGS.1,2A-B,8and11, in one or more examples, a method1100(seeFIG.11) for joining multiple substrates102of a workpiece104includes the method800ofFIG.8and continues from802to1102where a cap sealant member130is placed over the nut member110. The cap sealant member130includes a dome132and a cap flange134. The cap flange134configured to secure the cap sealant member130to the blind side108of the workpiece104. In another example, the method1100includes applying1104the lubricious coating204to the outer sleeve surface202of the sleeve member118. In this example, the method1100continues from1104to802ofFIG.8. In a further example of the method1100, the lubricious coating204on the outer sleeve surface202includes conductive features configured to provide electromagnetic energy protection to the workpiece104as the bolt member120becomes fully engaged with the nut member110. In yet another example, the method1100includes applying1106a conductive coating210to the outer sleeve surface202. In this example, the method1100continues from1106to802ofFIG.8.

With reference again toFIGS.1,2A-B,3,5-10,12,13and15-17, in still another example of the method800, the inserting804the sleeve member118includes limiting1202(seeFIG.12) further insertion of the sleeve member118into the joining bore116through the multiple substrates102based on a sleeve flange216at a proximal end214of an elongated sleeve body212of the sleeve member118. In still yet another example of the method800, the rotating808the bolt member120includes torquing1302(seeFIG.13) the bolt member120to become fully engaged with the nut member110.

With reference again toFIGS.1,2A-B,8and14, in one or more examples, a method1400(seeFIG.14) for joining multiple substrates102of a workpiece104includes the method800ofFIG.8and continues from804to1402where the lubricious coating204is applied to at least one of an inner sleeve surface218of the sleeve member118and an outer shank surface138of the shank portion126of the bolt member120.

With reference again toFIGS.1,2A-B,3,5-10,12,13and15-17, in another example of the method800, an outer shank diameter for the shank portion (126) of the bolt member (120) is substantially greater than an inner sleeve diameter for the sleeve member (118).

In yet another example of the method800, the sleeve member118also includes a cylindrical sleeve body220defining the central bore206. The cylindrical sleeve body220includes the outer sleeve surface202, an inner sleeve surface218facing the central bore206, a proximal end214relating to the working side106of the workpiece104and a distal end208relating to the blind side108of the workpiece104. In a further example, the shank portion126of the bolt member120includes a cylindrical shank body140. The cylindrical shank body140includes an outer shank surface138configured to face the inner sleeve surface218of the cylindrical sleeve body220as the bolt member120is inserted into the central bore206and becomes engaged with the nut member110. In an even further example, an outer shank diameter for the cylindrical shank body140is substantially greater than an inner sleeve diameter for the cylindrical sleeve body220. In another even further example of the method800, the providing812the interference fit502includes providing1502(seeFIG.15) the interference fit502within the joining bore116through the multiple substrates102in conjunction with a corresponding cylindrical shape of the joining bore116as the bolt member120becomes fully engaged with the nut member110.

In still another example of the method800, the sleeve member118also includes an elongated sleeve body212defining the central bore206. The elongated sleeve body212includes the outer sleeve surface202, an inner sleeve surface218facing the central bore206, a proximal end214relating to the working side106of the workpiece104and a distal end208relating to the blind side108of the workpiece104. In this example, at least the inner sleeve surface218is tapered from a larger inner sleeve diameter proximate the proximal end214to a smaller inner sleeve diameter proximate the distal end208such that the central bore206includes a frustoconical sleeve bore602.

In a further example, the outer sleeve surface202is cylindrical such that the elongated sleeve body212includes a cylindrical sleeve body220with the frustoconical sleeve bore602. In an even further example, the shank portion126of the bolt member120includes an elongated shank body604with an outer shank surface138configured to face the inner sleeve surface218as the bolt member120is inserted into the frustoconical sleeve bore602and becomes engaged with the nut member110. In this example, the elongated shank body604is tapered from a larger outer shank diameter proximate the head portion122of the bolt member120to a smaller outer shank diameter proximate the threaded portion124of the bolt member120such that the elongated shank body604includes a frustoconical shank body606. In an even yet further example, outer shank diameters for the frustoconical shank body606are substantially greater than corresponding inner sleeve diameters that define the frustoconical sleeve bore602. In another even yet further example of the method800, the providing812the interference fit502includes providing1602(seeFIG.16) the interference fit608within the joining bore116through the multiple substrates102in conjunction with a corresponding cylindrical shape of the joining bore116as the bolt member120becomes fully engaged with the nut member110.

In another further example, the outer sleeve surface202is tapered from a larger outer sleeve diameter proximate the proximal end214to a smaller outer sleeve diameter proximate the distal end208such that the elongated sleeve body212includes a frustoconical sleeve body702. In an even further example, the shank portion126of the bolt member120includes an elongated shank body604with an outer shank surface138configured to face the inner sleeve surface218as the bolt member120is inserted into the frustoconical sleeve bore602and becomes engaged with the nut member110. In this example, the elongated shank body604is tapered from a larger outer shank diameter proximate the head portion122of the bolt member120to a smaller outer shank diameter proximate the threaded portion124of the bolt member120such that the elongated shank body604includes a frustoconical shank body606. In an even yet further example, outer shank diameters for the frustoconical shank body606are substantially greater than corresponding inner sleeve diameters that define the frustoconical sleeve bore602. In another even yet further example of the method800, the radially expanding810includes causing1702(seeFIG.17) radial expansion of the frustoconical sleeve body702in conjunction with the frustoconical sleeve bore602of the frustoconical sleeve body702as the bolt member120becomes fully engaged with the nut member110. In this example, the providing812the interference fit502includes providing1704the interference fit704within the joining bore116through the multiple substrates102in conjunction with a corresponding frustoconical shape of the joining bore116as the bolt member120becomes fully engaged with the nut member110.

Referring generally toFIGS.1,2A-B,3,4A-C and18, by way of examples, the present disclosure is directed to a fastener system100for joining multiple substrates102of a workpiece104. The workpiece104has a working side106and a blind side108.FIGS.1,5-7and18disclose examples of the fastener system100.FIGS.1and18disclose examples of the fastener system100.FIG.2Ashows a side view of an example of a sleeve member118of the fastener system100.FIG.2Bshows a distal end view of the sleeve member ofFIG.2A.FIG.3shows an example of a nut member110of the fastener system100.FIGS.4A-Cshow examples of joining bores116in the workpiece104ofFIG.1with a countersunk portion402, a counterbored portion404and a cylindrical portion406.

With reference again toFIGS.1,2A-B,3,4A-C and18, in one or more examples, a fastener system100for joining multiple substrates102of a workpiece104includes a nut member110and a bolt member120. The workpiece104has a working side106and a blind side108. The nut member110includes a nut bore112with internal threads114. The nut member110configured for placement over a joining bore116through the multiple substrates102on the blind side108of the workpiece104. The joining bore116being tapered from a larger joining bore116diameter proximate the working side106of the workpiece104to a smaller joining bore116diameter proximate the blind side108of the workpiece104such that the joining bore116includes a frustoconical joining bore1802. The bolt member120includes a head portion122, a threaded portion124and a shank portion126extending between the head portion122and the threaded portion124. The shank portion126includes an elongated shank body604with an outer shank surface138. The elongated shank body604being tapered from a larger outer shank diameter proximate the head portion122to a smaller outer shank diameter proximate the threaded portion124such that the elongated shank body604includes a frustoconical shank body606. The outer shank surface138coated with a lubricious coating204. The bolt member120configured for insertion in the frustoconical joining bore1802through the multiple substrates102from the working side106of the workpiece104and configured for threaded engagement with the internal threads114of the nut member110. As the bolt member120becomes fully engaged with the nut member110, the frustoconical shank body606is configured to provide an interference fit1802within the frustoconical joining bore1802through the multiple substrates102in conjunction with a corresponding frustoconical shape of the frustoconical joining bore1802.

In another example of the fastener system100, the multiple substrates102include at least one composite material substrate128. In yet another example of the fastener system100, the nut member110is configured to be secured to the blind side108of the workpiece104. In a further example, the nut member110is configured to be secured to the blind side108of the workpiece104using mechanical fasteners, swagging or any other suitable fastening hardware/technique in any suitable combination. In still another example of the fastener system100, the nut member110also includes a nut plate assembly302with a nut304and a flange plate306captively retaining the nut304. The nut304includes the nut bore112. The flange plate306configured to be secured to the blind side108of the workpiece104with the nut bore112over the frustoconical joining bore1802through the multiple substrates102.

In still yet another example, the fastener system100also includes a cap sealant member130with a dome132and a cap flange134. The cap sealant member130configured for placement over the nut member110. The cap flange134configured to secure the cap sealant member130to the blind side108of the workpiece104. In another example of the fastener system100, the lubricious coating204includes indium, an indium alloy, tin, a tin alloy, bismuth, a bismuth alloy, aluminum, an aluminum alloy or any other suitable lubricious coating in any suitable combination. In yet another example of the fastener system100, the lubricious coating204on the outer shank surface138includes conductive features configured to provide electromagnetic energy protection to the workpiece104as the bolt member120becomes fully engaged with the nut member110. In still another example of the fastener system100, the outer shank surface138is coated with a conductive coating210to provide electromagnetic energy protection to the workpiece104as the bolt member120becomes fully engaged with the nut member110. In a further example, the conductive coating210includes indium, an indium alloy, tin, a tin alloy, lead, a lead alloy or any other suitable conductive coating in any suitable combination.

In still yet another example of the fastener system100, the bolt member120includes a metallic material. In a further example, the metallic material includes a stainless steel, titanium, a titanium alloy, a cobalt-chromium alloy, a nickel-titanium alloy or any other suitable metallic material in any suitable combination. In another example of the fastener system100, the head portion122of the bolt member120includes a torquing feature136. In a further example, the torquing feature136is configured to facilitate rotation of the bolt member120using a hex key torquing tool, a cross-tip driver torquing tool, a flat tip driver torquing tool, a hex socket torquing tool or any other suitable torquing tool. In yet another example of the fastener system100, the head portion122of the bolt member120includes a protruding head, a flush head, a countersunk head, a raised head, a recessed hexagon socket head, a recessed cross-tip head, a recessed flat tip head, a hexagon head or any other suitable type of head.

In still another example of the fastener system100, at the working side106of the workpiece104, the frustoconical joining bore1802through the multiple substrates102includes a countersunk portion402, a counterbored portion404, a cylindrical portion406or any other suitable geometry at the working side106compatible with the head portion122of the bolt member120. In still yet another example of the fastener system100, outer shank diameters for the frustoconical shank body606are substantially greater than corresponding frustoconical joining bore1802diameters that define the frustoconical joining bore1802. In a further example, the outer shank diameters are substantially greater than the corresponding frustoconical joining bore (1802) diameters by approximately 0.0005 inches, approximately 0.0010 inches, approximately 0.0015 inches, approximately 0.0020 inches, approximately 0.0025 inches or any other suitable difference measurement resulting the interference fit1802within the frustoconical joining bore1802. In another example of the fastener system100, the outer shank diameters are substantially greater than the corresponding frustoconical joining bore1802diameters by approximately 0.2 percent, approximately 0.4 percent, approximately 0.6 percent, approximately 0.8 percent, approximately 1.0 percent or any other suitable percentage resulting the interference fit1802within the frustoconical joining bore1802.

Referring generally toFIGS.1,2A-B,3,4A-C and18-23, by way of examples, the present disclosure is directed to methods1900,2200for joining multiple substrates102of a workpiece104. The workpiece104has a working side106and a blind side108.FIGS.1and18disclose examples of the fastener system100.FIG.2Ashows a side view of an example of a sleeve member118of the fastener system100.FIG.2Bshows a distal end view of the sleeve member ofFIG.2A.FIG.3shows an example of a nut member110of the fastener system100.FIGS.4A-Cshow examples of joining bores116in the workpiece104ofFIG.1with a countersunk portion402, a counterbored portion404and a cylindrical portion406.FIGS.19-21and23disclose various examples of the method1900.FIGS.19and22disclose various examples of the method2200.

With reference again toFIGS.1,2A-B,3,4A-C,18-21and23, in one or more examples, a method1900(seeFIG.19) for joining multiple substrates102of a workpiece104with a working side106and a blind side108includes securing1902a nut member110over a joining bore116through the multiple substrates102on the blind side108of the workpiece104. The nut member110includes a nut bore112with internal threads114. The joining bore116being tapered from a larger joining bore116diameter proximate the working side106of the workpiece104to a smaller joining bore116diameter proximate the blind side108of the workpiece104such that the joining bore116includes a frustoconical joining bore1802. At1904, a bolt member120is inserted in the frustoconical joining bore1802through the multiple substrates102from the working side106of the workpiece104until a distal end of the bolt member120contacts the nut member110. The bolt member120includes a head portion122at a proximal end, a threaded portion124at the distal end and a shank portion126extending between the head portion122and the threaded portion124. The shank portion126being tapered from a larger outer shank diameter proximate the head portion122to a smaller outer shank diameter proximate the threaded portion124such that the shank portion126includes a frustoconical shank body606. The shank portion126includes an outer shank surface138with a lubricious coating204. At1906, the bolt member120is rotated to engage the threaded portion124with the internal threads114of the nut member110. At1908, an interference fit1802is provided for the shank portion126of the bolt member120within the frustoconical joining bore1802through the multiple substrates102as the bolt member120becomes fully engaged with the nut member110in conjunction with a corresponding frustoconical shape of the frustoconical joining bore1802.

In another example of the method1900, the securing1902the nut member110includes securing2002(seeFIG.20) the nut member110to the blind side108of the workpiece104using mechanical fasteners, swagging or any other suitable fastening hardware/technique in any suitable combination.

In yet another example of the method1900, the nut member110includes a nut plate assembly302. In this example, the securing1902the nut member110includes captively retaining2102(seeFIG.21) a nut304of the nut plate assembly302in a flange plate306of the nut plate assembly302. At2104, the flange plate306is secured to the blind side108of the workpiece104with the nut bore112over the frustoconical joining bore1802through the multiple substrates102.

With reference again toFIGS.1,2A-B,19and22, in one or more examples, a method2200(seeFIG.22) for joining multiple substrates102of a workpiece104includes the method1900ofFIG.19and continues from1902to2202where a cap sealant member130is placed over the nut member110. The cap sealant member130including a dome132and a cap flange134. The cap flange134configured to secure the cap sealant member130to the blind side108of the workpiece104. In another example, the method2200continues from1902to2204where the lubricious coating204is applied to the outer shank surface138of the shank portion126of the bolt member120. In yet another example of the method2200, the lubricious coating204on the outer shank surface138includes conductive features configured to provide electromagnetic energy protection to the workpiece104as the bolt member120becomes fully engaged with the nut member110. In still another example, the method2200continues from1902to2206where a conductive coating210is applied to the outer shank surface138of the shank portion126of the bolt member120.

With reference again toFIGS.1,18-21and23, in another example of the method1900, the rotating1906the bolt member120includes torquing2302the bolt member120to become fully engaged with the nut member110. In yet another example of the method1900outer shank diameters for the frustoconical shank body606are substantially greater than corresponding frustoconical joining bore1802diameters that define the frustoconical joining bore1802.

Examples of fastener systems100and methods800,1100,1400,1900,2200for joining multiple substrates of a workpiece may be related to or used in the context of aircraft manufacturing. Although an aircraft example is described, the examples and principles disclosed herein may be applied to other products in the aerospace industry and other industries, such as the automotive industry, the space industry, the construction industry and other design and manufacturing industries. Accordingly, in addition to aircraft, the examples and principles disclosed herein may apply to the use of composite products in the manufacture of various types of vehicles and in the construction of various types of buildings.

The preceding detailed description refers to the accompanying drawings, which illustrate specific examples described by the present disclosure. Other examples having different structures and operations do not depart from the scope of the present disclosure. Like reference numerals may refer to the same feature, element, or component in the different drawings. Throughout the present disclosure, any one of a plurality of items may be referred to individually as the item and a plurality of items may be referred to collectively as the items and may be referred to with like reference numerals. Moreover, as used herein, a feature, element, component, or step preceded with the word “a” or “an” should be understood as not excluding a plurality of features, elements, components, or steps, unless such exclusion is explicitly recited.

Illustrative, non-exhaustive examples, which may be, but are not necessarily, claimed, of the subject matter according to the present disclosure are provided above. Reference herein to “example” means that one or more feature, structure, element, component, characteristic and/or operational step described in connection with the example is included in at least one aspect, embodiment and/or implementation of the subject matter according to the present disclosure. Thus, the phrases “an example,” “another example,” “one or more examples,” and similar language throughout the present disclosure may, but do not necessarily, refer to the same example. Further, the subject matter characterizing any one example may, but does not necessarily, include the subject matter characterizing any other example. Moreover, the subject matter characterizing any one example may be, but is not necessarily, combined with the subject matter characterizing any other example.

As used herein, a system, apparatus, device, structure, article, element, component, or hardware “configured to” perform a specified function is indeed capable of performing the specified function without any alteration, rather than merely having potential to perform the specified function after further modification. In other words, the system, apparatus, device, structure, article, element, component, or hardware “configured to” perform a specified function is specifically selected, created, implemented, utilized, programmed and/or designed for the purpose of performing the specified function. As used herein, “configured to” denotes existing characteristics of a system, apparatus, structure, article, element, component, or hardware that enable the system, apparatus, structure, article, element, component, or hardware to perform the specified function without further modification. For purposes of this disclosure, a system, apparatus, device, structure, article, element, component, or hardware described as being “configured to” perform a particular function may additionally or alternatively be described as being “adapted to” and/or as being “operative to” perform that function.

Unless otherwise indicated, the terms “first,” “second,” “third,” etc., are used herein merely as labels and are not intended to impose ordinal, positional, or hierarchical requirements on the items to which these terms refer. Moreover, reference to, e.g., a “second” item does not require or preclude the existence of, e.g., a “first” or lower-numbered item and/or, e.g., a “third” or higher-numbered item.

As used herein, the phrase “at least one of,” when used with a list of items, means different combinations of one or more of the listed items may be used and only one of each item in the list may be needed. For example, “at least one of item A, item B and item C” may include, without limitation, item A or item A and item B. This example also may include item A, item B and item C or item B and item C. In other examples, “at least one of” may be, for example, without limitation, two of item A, one of item B and ten of item C; four of item B and seven of item C; and other suitable combinations. As used herein, the term “and/or” and the “/” symbol includes any and all combinations of one or more of the associated listed items.

As used herein, the terms “coupled,” “coupling,” and similar terms refer to two or more elements that are joined, linked, fastened, attached, connected, put in communication, or otherwise associated (e.g., mechanically, electrically, fluidly, optically, electromagnetically) with one another. In various examples, the elements may be associated directly or indirectly. As an example, element A may be directly associated with element B. As another example, element A may be indirectly associated with element B, for example, via another element C. It will be understood that not all associations among the various disclosed elements are necessarily represented. Accordingly, couplings other than those depicted in the figures may also exist.

As used herein, the term “approximately” refers to or represents a condition that is close to, but not exactly, the stated condition that still performs the desired function or achieves the desired result. As an example, the term “approximately” refers to a condition that is within an acceptable predetermined tolerance or accuracy, such as to a condition that is within 10% of the stated condition. However, the term “approximately” does not exclude a condition that is exactly the stated condition. As used herein, the term “substantially” refers to a condition that is essentially the stated condition that performs the desired function or achieves the desired result.

InFIGS.1,2A-B,3,4A-C,5-7and18, referred to above, may represent functional elements, features, or components thereof and do not necessarily imply any particular structure. Accordingly, modifications, additions and/or omissions may be made to the illustrated structure. Additionally, those skilled in the art will appreciate that not all elements, features and/or components described and illustrated inFIGS.1,2A-B,3,4A-C,5-7and18, referred to above, need be included in every example and not all elements, features and/or components described herein are necessarily depicted in each illustrative example. Accordingly, some of the elements, features and/or components described and illustrated inFIGS.1,2A-B,3,4A-C,5-7and18may be combined in various ways without the need to include other features described and illustrated inFIGS.1,2A-B,3,4A-C,5-7and18, other drawing figures and/or the accompanying disclosure, even though such combination or combinations are not explicitly illustrated herein. Similarly, additional features not limited to the examples presented, may be combined with some or all the features shown and described herein. Unless otherwise explicitly stated, the schematic illustrations of the examples depicted inFIGS.1,2A-B,3,4A-C,5-7and18, referred to above, are not meant to imply structural limitations with respect to the illustrative example. Rather, although one illustrative structure is indicated, it is to be understood that the structure may be modified when appropriate. Accordingly, modifications, additions and/or omissions may be made to the illustrated structure. Furthermore, elements, features and/or components that serve a similar, or at least substantially similar, purpose are labeled with like numbers in each ofFIGS.1,2A-B,3,4A-C,5-7and18and such elements, features and/or components may not be discussed in detail herein with reference to each ofFIGS.1,2A-B,3,4A-C,5-7and18. Similarly, all elements, features and/or components may not be labeled in each ofFIGS.1,2A-B,3,4A-C,5-7and18, but reference numerals associated therewith may be utilized herein for consistency.

InFIGS.8-17and19-23, referred to above, the blocks may represent operations, steps and/or portions thereof and lines connecting the various blocks do not imply any particular order or dependency of the operations or portions thereof. It will be understood that not all dependencies among the various disclosed operations are necessarily represented.FIGS.8-17and19-23and the accompanying disclosure describing the operations of the disclosed methods set forth herein should not be interpreted as necessarily determining a sequence in which the operations are to be performed. Rather, although one illustrative order is indicated, it is to be understood that the sequence of the operations may be modified when appropriate. Accordingly, modifications, additions and/or omissions may be made to the operations illustrated and certain operations may be performed in a different order or simultaneously. Additionally, those skilled in the art will appreciate that not all operations described need be performed.

Further, references throughout the present specification to features, advantages, or similar language used herein do not imply that all the features and advantages that may be realized with the examples disclosed herein should be, or are in, any single example. Rather, language referring to the features and advantages is understood to mean that a specific feature, advantage, or characteristic described in connection with an example is included in at least one example. Thus, discussion of features, advantages and similar language used throughout the present disclosure may, but does not necessarily, refer to the same example.

Examples of the subject matter disclosed herein may be described in the context of aircraft manufacturing and service method2400as shown inFIG.24and aircraft2500as shown inFIG.25. In one or more examples, the disclosed methods and systems for associating test data for a part under test with an end item coordinate system may be used in aircraft manufacturing. During pre-production, the service method2400may include specification and design (block2402) of aircraft2500and material procurement (block2404). During production, component and subassembly manufacturing (block2406) and system integration (block2408) of aircraft2500may take place. Thereafter, aircraft2500may go through certification and delivery (block2410) to be placed in service (block2412). While in service, aircraft2500may be scheduled for routine maintenance and service (block2414). Routine maintenance and service may include modification, reconfiguration, refurbishment, etc. of one or more systems of aircraft2500.

Each of the processes of the service method2400may be performed or carried out by a system integrator, a third party and/or an operator (e.g., a customer). For the purposes of this description, a system integrator may include, without limitation, any number of aircraft manufacturers and major-system subcontractors; a third party may include, without limitation, any number of vendors, subcontractors and suppliers; and an operator may be an airline, leasing company, military entity, service organization and so on.

As shown inFIG.25, aircraft2500produced by the service method2400may include airframe2502with a plurality of high-level systems2504and interior2506. Examples of high-level systems2504include one or more of propulsion system2508, electrical system2510, hydraulic system2512and environmental system2514. Any number of other systems may be included. Although an aerospace example is shown, the principles disclosed herein may be applied to other industries, such as the automotive industry. Accordingly, in addition to aircraft2500, the principles disclosed herein may apply to other vehicles, e.g., land vehicles, marine vehicles, space vehicles, etc.

The disclosed systems and methods for associating test data for a part under test with an end item coordinate system may be employed during any one or more of the stages of the manufacturing and service method2400. For example, components or subassemblies corresponding to component and subassembly manufacturing (block2406) may be fabricated or manufactured in a manner similar to components or subassemblies produced while aircraft2500is in service (block2412). Also, one or more examples of the system(s), method(s), or combination thereof may be utilized during production stages (block2406and block2408), for example, by substantially expediting assembly of or reducing the cost of aircraft2500. Similarly, one or more examples of the system or method realizations, or a combination thereof, may be utilized, for example and without limitation, while aircraft2500is in service (block2412) and/or during maintenance and service (block2414).

The described features, advantages and characteristics of one example may be combined in any suitable manner in one or more other examples. One skilled in the relevant art will recognize that the examples described herein may be practiced without one or more of the specific features or advantages of a particular example. In other instances, additional features and advantages may be recognized in certain examples that may not be present in all examples. Furthermore, although various examples of the fastener systems100and methods800,1100,1400,1900,2200for joining multiple substrates of a workpiece have been shown and described, modifications may occur to those skilled in the art upon reading the specification. The present application includes such modifications and is limited only by the scope of the claims.