Fullerton Design 2 - IntroductionThe Fullerton Nut™:... its development, iterations, and conceptsI am (simply) a concept designer, inventor, concept illustrator, a photographer, and an artist; with the ability to use wood, glass, fiberglass, and metals to create and invent. Some might make the distinction that this may be considered to be a type of "Renaissance Man" mentality; however, I wouldn't make that definition of myself. I am not an engineer, nor a Lawyer, nor am I anything else. Simply, in my lifetime, I have just had to learn, by the "hard knocks" method, about what it requires to create; and especially, of what "hard knocks" method of creation it requires to keep those creations. In that time, I have developed a phylosophy (especially, from history) of which "hard knocks" methodology has been held by others to be true as well. One of these philosophical points have been that it is the quality of what has been created and, the test of, time that defines its own exclusivity and value - not quantity. The production of an idea begins to take its physical form, first, as a prototype. For a quick course in prototyping, and the gestation of producing a refined workable product, it will be finally evaluated in its repeatability when manufactured; a truly scientific viewpoint of the test. All ideas begin in the "rough", or as a prototype. Prototyping can (and should) be measured in "trimesters". TRIMESTERS
The fundemental conceptual design, of this idea has been made up from three basic parts: The Outer Body and the Top Cap forms one "half" of the basic design; and are two exterior parts. The Thread Segments make up the interior threaded (or ramp) surface of the fastener. This physical aspect of the design is what NASA engineers have defined as the "Fusticonical curve"; and what is elucidated as the other "half" of the functional components of this threaded fastener. The other two components (the outer body and the top cap) simply work in conjunction; as well as encase the thread segments. The threads of an ordinary nut, or fastener, are helical (circular) in construct and act as a simple ramp (or continuous, advancing, line) along the inside wall of the nut; defining the interferance angle to the fastened surface. It is the mechanical property of the interference intersections of the two ramp angles (bolt and nut thread) which produces the mechanical and torqable bond numbers between the surface within the fastener and to the fastened surface; the amount is dependant upon the adhesion factor and also and the qualities of materials used here. However, the threaded fastener segments (in the contracted position) does exactly the same thing, except for one difference: How do the thread segments expand, when the nut is pushed onto a bolt ? Well, the answer is simple; and an integral part of the Fullerton nut™ "Zip" design. The fasteners threaded segments are chamfered at the top and the bottom; so that these segments push up and out, as the segmented threads pass by the bolt's threads. Also, a normal nut configured fastener's design will only allow one side of the threaded ramp surface area to come in contact with the bolt's threaded ramp; thus, the normal nut only has a one-side-to-one-side surface area contact design. In a fusticonical curve, the divided thread segments also allow both sides of the thread ramp to come in deeper contact with the mated bolts threads (or ramp) making the interference junction. This means that more surface area (thread) is in contact, as the nut is tightened, and the fusticonical curvature configuration (surface area) "draws" (or attracts) the ramp closer and deeper into the curve of the thread itself. Once the bolt head engages the surface, a technician simply tightens the fastener the same as he would a normal nut. The thread segments, because of the increased surface area of contact, actually contacts and grips the bolt tighter. This grip action is very similar to a "Chinese finger trap" toy - the harder you pull, the tighter the surface contact gets; allowing for higher torque and load (pull) capabilities than conventional nuts !! The interesting point of this design is that the fastener is simply pushed down the full length of the bolt and the segments will re-engage the bolts threads at, almost, a torqued position. This means that the nut has to be turned only a small amount to enable thread grip and torque down the bolt into position; usually this is no more than a third of a full rotation; depending upon the angle acutness of the thread ramp slope to the fastened surface. Making this theoretical design simplified, functionally better, and then reproducable falls well within the realm of the second realm of the trimester.
Necessary, and fundamental, design changes should, and will, be implemented along with that part of the design undergoing testing as it progresses towards improving the basic concept; which started from the first trimester. The design changes were made, to what is now being called the Generation II version; having greatly improved the concept (well beyond first concept/trimester) and brought the nut back into the scope of an '"acceptable design". Manufacturing, repeatability, and costs are (now) at a level well within the realm of what is acceptable for the consumer and the manufacturer. Many iterations of the original fastener sprang up around these "Gen-II" design changes. However, the design had not reached the acceptable "second trimester" phase of development: well into Generation III. More improvements were made. Reliability improved, greatly, and (at the same time) manufacturing costs/methods improved. The manufacturing methodology, and design change implementions, improved the original concept to the point that the part finally reached the third trimester phase of prototyping. Currently (in the Gen-IV version of the design) robotic manufacturing capabilities of the concept have brought the cost, reliability, and quality well within the designs of the customer and the differing markets; third trimester. The current configuration differs from the original ZipNut® design, in that it eliminates:
Other design elements, that differ from the original basic (ZipNut®) Fullerton nut concept, have been incorporated into the new patent applications and passed on to my patent attorney to file.
By using the on/off iteration with modifications, a turnbuckle could be fashioned
to quickly go to the prescribed area on the male thread to place the turnbuckle in the "taunt" position.
Conversely, to disassemble would also eliminate many revolutions; this
iteration modification would originate with #18. An example of a use, of this turnbuckle, would be on a smaller sailboat that has to dismantle and reassemble the mast as the person is sailing. This iteration will be used in the fastening of concrete pre-casted wall sections to each other and the floor. This device will use the quick clean thread design. This iteration would use the new on/off principal to attach and detach hydraulic and air lines above one inch with safety lock. This iteration would use the new on/off principal to attach and detach hydraulic and air lines below one-inch diameter. This iteration would be a blind flat plain multi fastener used to attach automotive air bags to steering wheel mechanism by simple "push" effort. This iteration would be used on automotive wheel bearings to maintain torque load with a locking safety device. This iteration would be used to set and maintain tension load on the end of steel cable as a fastening device. This iteration would be used to maintain preload on rebar rods used in pre-stressed concrete such as bridges and dams. This iteration would be used to join concrete rebar sections. This iteration of the threaded fastener would be made to meet, or exceed, Class 8. The fastener would have two sets of "points" on the outside of the case. Between the upper and lower case is a programmed fracture point. At this time, bolting two steel beams together requires two men; one to feed a bolt through, hopefully, aligning holes in the two beams - if the bolt can be inserted properly without stripping threads. The other worker fits a nut to the exposed end of the bolt, and then both men go about tightening the combination. With this iteration, one man can feed a special bolt with an Allen socket in the leading end of the bolt through the aligned holes in the beams. If thread stripping occurs, he can continue. When the bolt has completed its journey, the duplex fastener is pushed on. A double socket wrench is placed over the nut. In the center of the duplex socket wrench is an Allen probe; used to hold the bolt in a fixed position. The duplex sockets will tighten the fastener until the top or smaller socket reaches a pre-set required torque - at this time, the top of the fastener (the 12 point part) will fracture at its base. The top area (12 point) will be anodized a bright color (red) with the area missing, an inspector will know the fastener has been torqued to the required limit. The ¾-inch unit will fracture at seventy-five pounds. This iteration of the threaded fastener concept would have the case top cap and threads made of 6061 aluminum or stainless steel. The primary use of this fastener would be to secure aluminum wheels to automobiles. The thread structures would vary from the normal threaded fastener configuration, as these threads would have to have redundant locking features and vibration resistant. The top cap/pin unit would double as a security lock requiring a key. The release key would be octagonal. The testing of the Porsche wheel nut, by Porsche exhibited torque loads past 300 lbs. without failure (the only failure in the Porsche tests were the actual wheel studs). Since a N.A.S.A. ½ inch nut has fractured an inconel bolt in testing by Almay Test Labs, this is not surprising. This iteration is in advanced concept form ready for pre-production field-testing. This iteration would be in a series in sizes up to one half inch. The concept would utilize the same plastic with fillers as in example #2 while being different in design or requirement. The thread segments would also be of the hard plastic material. The uses would be of the light load requirement such as furniture assembly, automotive trim, household use (wall brackets, etc.) aircraft accessory, any light load quick assembly disassembly where one would normally use small spot weld, clips, tinnamon fastener or pop rivets. This iteration is in advanced concept form and ready for preliminary field-testing. This iteration of the threaded fastener would be used by public gas companies such as P.G. & E. to connect the incoming gas line to a meter and then to the house gas line. The problem with the fastener used to date is two-fold:
There is a growing group of people that will then surreptitiously change the disk back to the washer and thus gaining free gas. The description of how to do this, and materials required, are available in the underground press. This iteration would have magnetic combination (some positive - some negative) holding the thread segments from free turning with the proper magnetic combination socket by turning with normal tools the coupler will free spin The Sacramento branch of P.G. & E., when supplying a gas meter on a stand to test this concept, informed me that in the Sacramento District alone several hundred meters have been destroyed by Cross threading but even of... This iteration is in late concept and ready for initial field test. This iteration of the threaded fastener concept would use a completely unique thread design that would dramatically reduce the cost of construction. This iteration would not have the holding ability; high-test results or repeatability of a normal threaded fastener fastener nut would easily qualify as a class-one or class-two fastener. This would be a version of the threaded fastener concept especially designed to fill the need of a low cost every day nut sold in hardware stores. This iteration has the ability to change from a threaded fastener to a normal fastener with the twist of the top cap. In some uses it would be an advantage to eliminate the threaded fastener capability of the fastener making the fastener stay in place without resistance on a threaded shaft or during removal while the threaded male component is in a movement or vibratory condition (the normal threaded fastener will always continue to the base of the male threaded component with minimal urging). The elimination of the "Zip" capability is accomplished by simply twisting the top cap one-quarter turn counter clockwise. This iteration has the ability to, once the fastener has been torqued to a pre-set limit, free turn; eliminating the possibility of warping the device being secured or the fracture of a part of flange being secured by over torquing. The fastener, at manufacturing, will have a pre-set torque limit with a plus or minus of one percent. At this time, it is estimated that the manufacturing cost will be ten percent above a comparable threaded fastener. The use will be in any of the many torque sensitive applications. This iteration, originally designed for the Space Station as a strut, would have a large commercial market; such as a lightweight tent structure connector, a construction space bar, an emergency retaining bar - to name a few uses. This iteration can be easily placed into a geodesic structure, has high strength capability and extremely light in weight, quick to extend or collapse upon command. This iteration produces a normal configured fastener with the ability to be quickly removed bys imply twisting the Top Cap one quarter turn counter clockwise after releasing tension. The concepts with modification would be included in the threaded fastener Clamp. The concept has completed the pre-production prototype stage and is now in engineered dimensioned drawing form ready for production field-testing. This iteration of the threaded fastener concept would be to eliminate the exposed screw connecting the replacement tooth cap to the base unit. At this time, the accepted procedure (SEE attached) produces a thermal conducting path from above the tooth cap (exposed) to the jawbone. This concept would eliminate this problem by simply constructing a tooth cap casting with an internal threaded fastener configuration resulting in a superior product both for thermal conductivity and cosmetic appearance by eliminating the exposed retaining screw. Originally, the iteration of the Generation II (ZipNut®) Fullerton nut was requested by the U.S. Air Force as a solution to a problem with "Thermal Flex"; now being experienced with high speed (and super sonic) aircraft. The friction heating of the "skin" of modern jet aircraft will cause inspection panels to release in flight; an opportunity for catastrophic failure. During a discussion between the inventor (Robert Fullerton), NASA officials, and Boeing Engineers the problem was brought up resulting in this inventors (Robert Fullerton) invitation for a meeting with Air Force personnel of Vandenberg Air Force Base. The design criteria was a mechanical lock (Male/Female) fastener that would operate without the necessity of special tools. The Fullerton nut™ Panel Fastener has a positive lock and will "Zip on" with the ability to disengage utilizing a Phillips head screwdriver. The Panel Fastener was disclosed to Boeing Engineer Paul Smudde (of Huntington Beach) as well as Mr. Pete Kenourgios of LeoPete Aircraft (Salt Lake City), Utah. Mr. Kenourgios is interested in using the Panel Fastener on inspection panels his company manufactures for the C-5 Aircraft. This interest led Mr. Kenourgios to discuss the Panel Fastener with F.A.A. representatives, resulting in favorable interest in the Panel Fastener for aircraft use other than the C-5 Galaxy Aircraft. A second area of interest in the Panel Fastener has been in the area of electrical sign inspection panels, to eliminate unauthorized entry. Modifications to the "Male Bolt" would accomplish this security feature. This iteration, constructed (case and top cap) of plastic with tillers, thread segments of stainless steel. The telephone company dedicates a major portion of its installation instruction document to the removal and replacing of fasteners in a "gang" fixture. A study illustrated that one in twelve nuts will "cross-thread", or gall, on installation or adjustment; primarily caused by the repairman not "seating" the bolt thread properly prior to using the pneumatic assembly tool. Considering most installations, or replacements, are carried out high above ground in all conditions one can understand the difficulty in properly securing 18 fasteners as per instruction. When one also considers the cost of men and equipment, the cost of the fastener soon becomes insignificant. This iteration is well in pre-production and is ready for field-testing. This iteration would be in the small series (average 10-32) with Body and Top Cap made of plastic with fillers and the threads of stainless steel. The design of this fastener would permit for the quick assembly of electronic components, while eliminating "chatter" or grounding of the component. A second benefit would be, by incorporating the threaded fastener design in the base of the electronic device, the component, with threaded studs, could be permanently attached to the chassis by simply pushing the component to the chassis; a task easily accomplished by robotics. In some cases the components future removal could be handled by simply using screws in place of fixed threaded studs affixed to the component. This iteration has completed the concept stage and is ready for pre-production prototyping. This iteration of the threaded fastener would be made of high strength fibers held in a polymer material with strength characteristics approaching that of metal. This fastener would be radiolucent or permeable to x-rays and other forms of electromagnetic radiation. As a fixation device, this threaded fastener would not shield a fracture, tumor or blood clot in the x-ray process. An example would be that of a "halo" used to hold the head in fixed position following neck trauma. The "halo" has a series of spikes placed in a ring with the pointed end directed to the center of the ring. The ring, placed over the head, allows the pointed spikes to secure the head firm. Movement of the ring is held in place by a mechanical structure based on the shoulder. By incorporating the threaded fastener into the ring made of composite material, x-rays of the head would be possible. This theory would also be applied to a medical clamp device to replace pins when repairing broken bones. This iteration has completed the concept stage and is now ready for concept engineering. United Defense (Track Layers and verious other vehicles) Fullerton Design, a couple of years ago, issued a request for bid (RFQ) for an initial order of 2,500,000 ¾-inch on/off Fullerton Nut™ (originally called the "ZipNut®") nut to be used to replace the track pads on the M88-A2 Hercules Recovery Vehicle. Fullerton Design developed a new version of the On/Off Fullerton nut to fill this order. This new On/Off threaded fastener, filling the design requirements set up by United Defense, would have required no "patent pending"; as it would have been assigned to the company and closing. The reason for the interest, by United Defense, is due to the M88-A2 having 168 track links with 2 pads per link. Each pad requires two ¾-inch nuts. The time required to change these links every 500 miles, is 14 hours. It is felt that the new On/Off nut will be able to cut this time; as testing has shown that 52 On/Off Nut's can be installed in the length of time it takes to install one normal nut. This test did not take into consideration cross-threading, which would require more "down time" to dismantle the track pad, being replaced, and re-installing a new pad; resulting in the additional loss of that pad. Since cross-threading is virtually eliminated, using the threaded fastener, the "down time" issue was ignored. Subsequent discussions with Mr. Charles W. McCraw, Associate Design Engineer, United Defense steel product division; produced interest in the new concept being expanded to ⅝-inch and 9/16-inch to be used a new track designs being released that year. United Defense is interested in retrofitting in supplying the M88 track with a ¾-inch ZipNut® for all the manufacturing. A rough estimate usage was 4,000 vehicles; at 312 pads per vehicle. Pads were to be purchased twice a year equaling 4,992,000 nuts per year plus retrofitting. United Defense is also looking into other areas of various track-laying vehicles that could use the On/Off threaded fastener. Their company is responsible for track combat vehicles including the Bradley Fighting Vehicle, the M-109 self-propelled Howitzer, the M88-A2 Hercules Recovery Vehicle, the ACE Armored Combat Earthmover, the M-113. These are all candidates for the various threaded fastener concepts. ...
And this represents just one typical branching of iterations. |