METHOD FOR FORMING THREADS IN A RIVET FASTENER

Abstract

The present teachings relate to a method for forming a rivet fastener, the method comprising: a) placing a portion of a body of the rivet fastener into a head opening of a head of the rivet fastener, wherein the head has a head opening defined by an interior threaded portion; b) inserting a swaging tool through the head opening and into the body hole and applying a deformation force onto the portion of the body within the head, wherein the deformation force causes the portion of the body that resides within the head to be permanently deformed into an external threaded portion reciprocal to and engaged with the internal threaded portion of the head; c) removing the swaging tool from the body and the head; and d) inserting a mandrel into the body hole to form the rivet fastener; wherein the formed rivet fastener has a body removably secured to the head.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent Application No. 63/833,771 filed on Jan. 16, 2025, which is incorporated herein by reference in its entirety for all purposes.

FIELD

The present teachings relate to a method for forming threads on a rivet body. The threads may find use in engaging with and allowing for the removal of a rivet head. The method may find use in providing for a rivet fastener. The fastener may find use as a blind rivet with a removable head.

BACKGROUND

Traditional blind rivets are useful for permanently fastening two sheets of material together. The blind rivet achieves this permanent fastening by plastic deformation of one end of the rivet. Once plastic deformation of the rivet occurs, the only way to remove the fastener is by a destructive removal method. A common destructive removal method is drilling out the body of the fastened rivet. Thus, traditional blind rivets are not optimized for use where it is known that the fastener might need to be removed in the future.

One such elegant solution for a rivet fastener is provided in U.S. Pat. No. 12,258,987, which is incorporated herein by reference in its entirety for all purposes. The teachings provide for a removable fastener that allows for a first panel to be removably affixed to a second panel that is mechanically constrained by the rivet fastener. The rivet fastener includes a body with an exterior portion that can be affixed to a head that has a reciprocal interior threaded portion. Removal and reattachment of the head allows for the first panel to be removably affixed to the second panel without requiring the typical destructive removal.

Traditional methods for forming threads include tapping, milling, turning, broaching, rolling, or the like. However, these methods have been found to collapse the hollow rivet body when used to form threads on an exterior portion thereof, as large amounts of pressure may need to be applied.

Therefore, what is needed is a method to form a blind fastener that combines a rivet body with a detachable head. More specifically, a method to form threads on a rivet body, while maintaining the integrity of the rivet body, and still allowing for it to be removably affixed to the detachable head. Such removal may still allow for a first panel to be removably affixed to a second panel.

What is needed is a blind rivet-style fastener that allows for temporary unfastening. What is needed is a fastener with a separate body and head that can be attached to fasten panels and removed to allow for the disassembly of panels. What is needed is a method for forming threads on an exterior portion of the rivet body without crushing, collapsing, or otherwise deforming the rivet body.

SUMMARY

The present teachings relate to a method for forming a rivet fastener, the method comprising: a) placing a portion of a body of the rivet fastener into a head of the rivet fastener such that a portion of the body is located within a head opening of the head, wherein the head opening is defined by an interior threaded portion of the head, wherein the portion of the body is cylindrical and includes a body hole extending along at least a portion of a longitudinal length of the body, wherein the portion of the body which resides within the head opening has an external surface that is substantially smooth, and wherein when the body is inserted into the head, the head opening aligns with the body hole; b) inserting a swaging tool through the head opening and into the body hole and applying a deformation force onto the portion of the body within the head, wherein to generate the deformation force, the swaging tool exerts an outward radial force to the portion of the body that resides within the head opening, and wherein the deformation force causes the portion of the body that resides within the head to be permanently deformed into an exterior threaded portion reciprocal to and engaged with the internal threaded portion of the head; and c) optionally, removing the swaging tool from the body and the head, and wherein the exterior threaded portion of the body is removably engaged with the interior threaded portion of the head to removably secure the body to the head.

The present teachings relate to a method for forming a rivet fastener, the method comprising: a) placing a portion of a body of the rivet fastener into a head opening of a head of the rivet fastener, wherein the head includes a centering feature formed as a protrusion on a bottom surface of the head and extending towards another portion of the body, wherein the head opening is defined by an interior threaded portion of the head, wherein the interior threaded portion extends along an entire longitudinal length of the head, including the centering feature, wherein the portion of the body is cylindrical and includes a body hole extending along at least a portion of a longitudinal length of the body, wherein the portion of the body which resides within the head opening has an external surface that is substantially smooth, and wherein when the body is inserted into the head, the head opening aligns with the body hole; b) inserting a swaging tool through the head opening and into the body hole and applying a deformation force onto the portion of the body within the head, wherein to generate the deformation force, the swaging tool exerts an outward radial force to the portion of the body that resides within the head opening, and wherein the deformation force causes the portion of the body that resides within the head to be permanently deformed into an exterior threaded portion reciprocal to and engaged with the internal threaded portion of the head; c) removing the swaging tool from the body and the head, wherein the exterior threaded portion of the body is removably engaged with the interior threaded portion of the head to removably secure the body to the head; and d) inserting a mandrel into the body hole to form the rivet fastener.

The present teachings relate to a rivet fastener formed by the method, the rivet fastener includes: a) the body having: i) a first cylindrical portion with a first diameter, ii) a second cylindrical portion with a second diameter, wherein the first diameter is larger than the second diameter such that a shoulder is formed between the first cylindrical portion and the second cylindrical portion, iii) a third cylindrical portion with a third diameter and having the exterior threaded portion, and iv) a body hole extending along an axis of the body through the first cylindrical portion, the second cylindrical portion, and the third cylindrical portion; b) the mandrel having: i) a mandrel shank, and ii) a mandrel head at an end of the mandrel shank opposite the head; and c) the head having: i) a head opening defined by an interior threaded portion, ii) one or more head protrusions on a surface facing toward the mandrel head and configured to embed into a first panel, and iii) the centering feature which is formed as the protrusion and faces toward the mandrel head and which is configured to align the fastener with a first panel hole of the first panel; wherein the mandrel shank at least partially occupies the body hole; wherein the mandrel head is located outside of the body and opposite of the exterior threaded portion of the body; and wherein the rivet fastener is configured to be deformed from an undeformed state into a deformed state.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a transparent cross-sectional view of a fastener.

FIG. 2A is a cross-sectional view of a fastener in an undeformed state through a panel assembly.

FIG. 2B is a cross-sectional view of a fastener in a deformed state through a panel assembly.

FIG. 3 is a top view of a head of a fastener.

FIG. 4 is a top view of a head of a fastener.

FIG. 5 is a cross-sectional view of a head of a fastener.

FIG. 6 is a cross-sectional view of a head of a fastener.

FIG. 7A illustrates an insertion of a body into a head in a method of forming a rivet fastener.

FIG. 7B illustrates a body inserted into a head in a method of forming a rivet fastener.

FIG. 7C illustrates an insertion and rotation of a swaging tool in a method of forming a rivet fastener.

FIG. 7D illustrates a removal of a swaging tool in a method of forming a rivet fastener.

DETAILED DESCRIPTION

The explanations and illustrations presented herein are intended to acquaint others skilled in the art with the present teachings, their principles, and their practical application. The specific embodiments of the present teachings as set forth are not intended as being exhaustive or limiting of the present teachings. The scope of the present teachings should be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. The disclosures of all articles and references, including patent applications and publications, are incorporated by reference for all purposes. Other combinations are also possible, as will be gleaned from the following claims, which are also hereby incorporated by reference into this written description.

Method for Forming a Rivet Fastener

The present teachings relate to a method for forming a rivet fastener. The method may include one or more of the following steps: placing a portion of a body of the rivet fastener into a head of the rivet fastener such that a portion of the body may be located within a head opening of the head; inserting a swaging tool through the head opening and into the body hole; applying a deformation force onto the portion of the body within the head; removing the swaging tool from the body and the head; inserting a mandrel into the body hole through the body; inserting a mandrel into the body hole to form the rivet fastener; leaving the swaging tool in place within the body hole so that the swaging tool becomes the mandrel, the like, or any combination thereof.

A method for forming a rivet fastener may include placing a portion of a body of a rivet fastener into a head. A portion of the body may be placed into a head opening of the head such that a portion of the body is located within the head. The head opening may be defined by an interior threaded portion of the head. The portion of the body placed within the head may have a cross-sectional shape substantially reciprocal or similar to the cross-sectional shape of the head opening (e.g., along a longitudinal or central axis). The portion of the body placed within the head may be cylindrical. The portion of the body placed within the head may include or be free of a body hole prior to insertion into the head. A body hole may be formed into the body prior to, simultaneous with, and/or after insertion of the body into the head. A body hole may extend along at least a portion of or an entire longitudinal length of the body. The portion of the body that is inserted into the head may have a substantially smooth external surface prior to, during, and/or after insertion into the head. Once the portion of the body is inserted into the head, the head opening may align with the body hole. Alignment may be concentric, coaxial, or both. The head may be placed on the portion of the body such that the head opening may align with the body hole. The portion of the body may be inserted into the head opening. An end of the body portion may be inserted into the head such that it rests within the head opening (e.g., below flush), rests flush with an outer surface of the head, or rests above and outside of the head opening (e.g., above flush). The body may be inserted from an upper surface and/or a lower surface of the head. The body may be inserted at a lower surface of the head through the head opening until a first cylindrical portion abuts the head (e.g., bottom surface, centering feature). A centering feature may aid in alignment of the body with the head during insertion.

Placement of the body into the head may be manual, automated, or both. For example, a user may manually insert the body into the head. For example, a robotic arm or other automated tool may insert the body into the head. Heat may be applied to the body, head, or both prior to and/or during placement of the body into the head. Heat may help facilitate the deformation of the body to fit within the head opening.

A method for forming a rivet fastener may include inserting a swaging tool into the body. The swaging tool may be inserted into the body hole. The swaging tool may be inserted through the head opening. The swaging tool may be inserted first into the head opening and then into the body hole, first into the body hole and then into the head opening, or simultaneously into both the head opening and the body hole. The swaging tool may be inserted from a top end of the body, a bottom end of the body, or both. The top of the body may include the portion with the head placed thereon. The bottom of the body may include the portion of the body extending below the head, including a first cylindrical portion, a second cylindrical portion, or a combination thereof. The bottom end may be opposite the top end, opposite the head, or both. Insertion of the swaging tool may be performed prior to, simultaneously with, or after placement of the body into the head.

Insertion of the swaging tool may be manual, by automated equipment, or both. Heat may be applied to the swaging tool, body, or both prior to and/or during insertion of the swaging tool into the body. Heat may help facilitate insertion of the swaging tool into the body.

A method for forming a rivet fastener may include using the swaging tool to apply a deformation force. The deformation force may be applied onto the body. The deformation force may be applied onto the portion of the body that resides within the head. The deformation force may be applied onto an interior surface of the body, such as a surface defining a body hole. The deformation force may transfer from an interior of the body to an exterior surface of the body. To generate the deformation force, the swaging tool may exert an outward radial force on the portion of the body that resides within the head, the portion of the body located within the head opening which is threaded, or both. The deformation force may cause the portion of the body that resides within the head to be permanently deformed. The deformation may result in an exterior threaded portion. The exterior threaded portion may be reciprocal to and engaged with the internal threaded portion of the head. After the deformation force is applied, the exterior threaded portion of the body may be removably engaged with the interior threaded portion of the head to removably secure the body to the head.

Applying a deformation force on the body may utilize heat. Heat may aid in the deformation of the portion of the body upon application of the deformation force. Heat may be applied prior to, simultaneously with, or even after the application of the deformation force. Heat may be applied to the portion of the body that will reside within the head before the portion of the body is placed within the head opening. Heat may be applied to the head, the portion of the body that resides within the head, or both while the deformation force is being applied. Heat may be applied both prior to the deformation force and during the application of the deformation force.

A mechanical force may be applied to the swaging tool. The mechanical force may cause the swaging tool to apply the deformation force onto the body. The mechanical force may be an axial force, a rotational force, the like, or a combination thereof. An axial force and a rotational force may be applied to the swaging tool simultaneously. An axial force and a rotational force may be applied separately. The axial force may be applied first, followed by the rotational force, or vice versa. The axial force and rotational force may be applied in repetition (e.g., the axial force may be applied first, then the rotational force may be applied, followed by the axial force again). The mechanical force may be applied continuously. The mechanical force may be applied incrementally.

Application of a deformation force from the swaging tool to the body may be manual, by automated equipment, or both. At least partial automation may allow for the provision of a sufficient deformation force to result in deformation of the body. The magnitude and sequence of mechanical forces may be adjusted to optimize thread formation, minimize material damage, or both.

The swaging tool may have a continuously consistent width, be tapered, or both. Tapering may allow for ease of alignment for insertion into the body hole. Tapering may be a diameter that increases along all or a portion of the longitudinal axis of the swaging tool. A tapered swaging tool may be a tapered implement. The swaging tool may maintain a consistent diameter along all or a portion of its longitudinal axis.

The swaging tool may include one or more protrusions. The one or more protrusions may function to apply the deformation force onto the body, create one or more grooves, push the body into the interior threads of a head, or a combination thereof. The one or more protrusions may extend substantially perpendicularly and/or be offset (e.g., between perpendicular and parallel) from the longitudinal axis of the swaging tool. The one or more protrusions may push the portion of the body within the head into the internal threaded portion of the head when a mechanical force is applied to the swaging tool. The one or more protrusions may include one or more helical ridges, individual pointed protrusions, or both. The one or more protrusions may push the portion of the body into the internal threaded portion of the head when a mechanical force is applied to the swaging tool. The swaging tool may have a combination of one or more helical ridges and one or more individual point protrusions. One or more protrusions may function as a key. It is possible that the body may include a slotted channel along at least a portion of the body hole. The one or more protrusions may first align with the slotted channel before and during insertion of the swaging tool into the body. The configuration and arrangement of the one or more protrusions may be selected to optimize thread formation, minimize material stress, minimize material damage, and/or provide a desired engagement profile with the head.

The swaging tool may comprise one or more swaging tool materials. The one or more swaging tool materials may comprise one or more ceramics, metals, carbon-based materials, compounds, alloys, the like, or a combination thereof. The one or more metals may comprise steel, aluminum, titanium, copper, brass, tungsten, osmium, any alloy thereof, the like, or any combination thereof. The one or more carbon-based materials may include graphene, carbide, carbon fiber, or a combination thereof. The one or more swaging tool materials may comprise one or more nanomaterials. The one or more swaging tool materials may have a higher tensile strength, compressive strength, hardness, fatigue strength, elastic modulus, thermal softening temperature, the like, or a combination thereof than that of the material of the body and/or the head.

A method for forming a rivet fastener may include removing the swaging tool. Removal of the swaging tool may expose the body hole, allow for insertion of a mandrel into the body, or both. The swaging tool may be removed from the body, the head, or both. Removal of the swaging tool from the body hole may require disengaging (e.g., unthreading, rotation) the swaging tool. Removal of the swaging tool may require mechanical force. Removal of the swaging tool may require one or more opposite mechanical forces to those used for applying the deformation force. The swaging tool may be removed from the top end, bottom end, or both of the body.

A method for forming a rivet fastener may include inserting a mandrel. The mandrel may be inserted to create a rivet fastener. The mandrel may be inserted into the body hole, through the head, or both. The mandrel may be inserted into the body hole through the top end and/or bottom end of the body. The mandrel may include a mandrel shank and a mandrel head. The mandrel shank may be integral with or affixed to the mandrel head. The mandrel shank may be removably affixed to the mandrel head by use of a snap-on feature, spring feature, a press-fit connection, or threading. The mandrel shank may be inserted into the body hole from either the top end or the bottom end of the body before the mandrel head is affixed thereto. The mandrel shank may be inserted into the body hole from either the top end or the bottom end of the body after the mandrel head is affixed thereto. In the case that the mandrel head is integral with the mandrel shake, the mandrel may be inserted through the bottom end of the body.

The method for forming a rivet fastener may be free of removing the swaging tool.

A method for forming a rivet fastener may include the swaging tool remaining in place within the body hole. Remaining in place may allow the swaging tool to function as and become the mandrel. The mandrel may include a mandrel shank and a mandrel head. The mandrel shank may be removably affixed to the mandrel head. The mandrel shank may be removably affixed to the mandrel head by use of a snap-on feature, spring feature, a press-fit connection, or threading. The mandrel shank may be used as the swaging tool. The swaging tool may be keyed reciprocally to at least a portion of the body hole so that the swaging tool may be inserted into the body hole through the top end or the bottom end of the body without the swaging tool applying a deformation force in the reciprocally keyed areas of the body. The keyed portion of the swaging tool may include the one or more protrusions. After the swaging tool applies the deformation force to the portion of the body within the head, the mandrel head may be affixed to the swaging tool such that the swaging tool becomes the mandrel.

Rivet Fastener

The present teachings may relate to a rivet fastener. The rivet fastener may be formed by the method for forming a rivet fastener as disclosed herein. The rivet fastener formed by the method may function to removably constrain a first panel to a second panel. The fastener may be permanently affixed to the second panel. The fastener may allow for the removal of the second panel from the first panel. The fastener may allow for re-constraint of the first panel to the second panel. The fastener may include a body, mandrel, head, or a combination thereof. The fastener may have a deformed state, an undeformed state, or both.

The fastener may include a body. The body may be deformed to permanently attach the body to a second panel. The body may occupy a first panel hole in a first panel. The body may occupy a second panel hole in a second panel. The body may removably affix the first panel to the second panel. The body may constrain the first panel between the second panel and the head. The body may allow for the first panel to be removed from the second panel non-destructively. The first panel may be removed from the second panel by removing the head from the body. The body may be a hollow tubular structure. The body may have a rounded or prismatic external shape. The external shape may refer to the periphery or cross-section (e.g., taken across the longitudinal axis). The body may have an outer perimeter that is circular, polygonal, or any other shape. The body may have one or more radial slots or holes along any portion of the body, which are one or more body openings. The body may have a hole through its axis, which is a body hole. The body may have two or more external diameters and cylindrical portions. The body may have three or more external diameters and cylindrical portions. The body may have a first diameter, a second diameter, and a third diameter. The body may have a first cylindrical portion, a second cylindrical portion, and a third cylindrical portion. The first cylindrical portion, second cylindrical portion, third cylindrical portion, or a combination thereof may be integrally formed. The body may have a shoulder between the first cylindrical portion and the second cylindrical portion. The body may have an exterior threaded portion. The exterior threaded portion of the body may be at an end of the body opposite the second cylindrical portion. The exterior threaded portion of the body may have the exterior threaded portion formed thereon. The exterior threaded portion of the body may interact with an internal threaded portion of the head to allow the head to be removably affixed to the body. The exterior threaded portion of the body may be on the third cylindrical portion. The body may be affixed to the head via a snap-in feature, a spring feature, or a press fir connection. The body may contain a mandrel within the body hole. The body may be deformed by the mandrel. The body may be installed without a mandrel by a clinching, welding, stacking, or other process.

The body may include a first cylindrical portion. The first cylindrical portion may occupy a first panel hole in a first panel when the fastener is fastening a first panel to a second panel. The first cylindrical portion may have a first diameter. The first cylindrical portion may have a first diameter that is larger than the diameter of a second panel hole. The larger diameter of the first cylindrical portion may prevent the first cylindrical portion from occupying the second panel hole. The first diameter of the first cylindrical portion may be larger than the second diameter of the second cylindrical portion. The first cylindrical portion of the body may reside between the second cylindrical portion of the body and the exterior threaded portion of the body. The first cylindrical portion of the body may reside between the second cylindrical portion of the body and the third cylindrical portion of the body. The first diameter may have a length less than or equal to the thickness of the first panel. The first cylindrical portion may include surface textures or surface features. The first cylindrical portion may have knurling, ribbing, or other surface features. The first cylindrical portion may be formed by the same deformation process used to create the deformed zone. The first cylindrical portion may not occupy the entirety of the first panel hole. The first cylindrical portion may have any shape suitable for the body.

The first cylindrical portion may have a first diameter. The first diameter may be the outermost diameter of the first cylindrical portion. The first diameter may be larger than the second diameter. The first diameter may be larger than the diameter of the second panel hole. The first diameter may be smaller than the diameter of the first panel hole.

The body may include a second cylindrical portion. The second cylindrical portion may occupy a second panel hole in a second panel. A portion of the second cylindrical portion opposite the first cylindrical portion may be deformed to create a deformed area. The diameter of the deformed area may be larger than the second diameter and the diameter of the second panel hole. The second cylindrical portion of the body may be inserted into the second panel hole until a shoulder of the body abuts the second panel, prior to creation of the deformed area, such that when the deformed area is created, the deformed area permanently constrains the second panel on the second cylindrical portion between the shoulder and the deformed area. The second diameter of the second cylindrical portion may be smaller than the first diameter of the first cylindrical portion. The second diameter may be larger than the diameter of the second panel hole. The second cylindrical portion may have a length that is greater than the thickness of the second panel. The second diameter may be the portion of the body opposite a threaded portion. The second cylindrical portion may have knurling, ribbing, or other surface features. The second cylindrical portion may have any shape suitable for the body. The second cylindrical portion may have a shape similar to or dissimilar to that of the first cylindrical portion.

The second cylindrical portion may have a second diameter. The second diameter may be the outermost diameter of the second cylindrical portion. The second diameter may be smaller than the first diameter. The second diameter may be smaller than the diameter of the second panel hole. The second diameter may be smaller than the diameter of the first panel hole.

The body may include a shoulder. The shoulder may prevent the first cylindrical portion from occupying the second panel hole. The shoulder may allow for the body to be permanently affixed to the second panel by abutting the second panel and constraining the second panel between the shoulder and the deformed area. The shoulder may be a radial plane between the first diameter and the second diameter. The shoulder may be formed by the difference in diameter between the first cylindrical portion and the second cylindrical portion.

The body may include a third cylindrical portion. The third cylindrical portion may be adjacent to the first cylindrical portion. The third cylindrical portion may be adjacent to the first cylindrical portion, opposite the second cylindrical portion. The third cylindrical portion may be the portion of the body that resides within the head during the method for forming a rivet fastener. The third cylindrical portion may include surface textures or surface features. The third cylindrical portion may have knurling, ribbing, or other surface features. Prior to the method for forming the rivet fastener, the external surface of the third cylindrical portion may be smooth. Prior to the method for forming the rivet fastener, the external surface of the third cylindrical portion may be smooth except for the surface textures or surface features (e.g., the third cylindrical portion may be free of threads but include a different surface texture). After the method for forming the rivet fastener, the exterior threaded portion may span at least a portion of or the entire longitudinal length of the third cylindrical portion.

The third cylindrical portion may have a third diameter. The third diameter of the third cylindrical portion may be smaller than the first diameter of the first cylindrical portion. The third diameter of the third cylindrical portion may be smaller than, larger than, or the same as the second diameter of the second cylindrical portion.

The body may include a deformed area. The deformed area may not exist prior to the installation of the fastener. The deformed area may not exist prior to the deformation of the fastener. The deformed area may permanently affix the body of the fastener to the second panel. The second panel may be positioned to abut the shoulder prior to creation of the deformed area. Creation of the deformed zone while the second panel abuts the shoulder may permanently bind the second panel to the body. The deformed area may prevent the removal of the second panel by having a diameter larger than the diameter of the second panel hole. The deformed area may be created by applying force to a mandrel, which transfers that force through a mandrel head into the body. The force on the mandrel head may transfer to a portion of the second cylindrical portion of the body until plastic deformation of the body is achieved. The deformed area may be created by axial compression of the second cylindrical portion sufficient to achieve plastic deformation of the second diameter.

The body may include an exterior threaded portion. The exterior threaded portion of the body may allow for the body to be removably affixed to a head. The exterior threaded portion of the body may interact with an interior threaded portion of the head. The exterior threaded portion of the body may allow for the head to be removed from the body when the head is rotated in one direction relative to the body. The exterior threaded portion of the body may allow for the head to be affixed to the body when the head is rotated in an opposite direction relative to the body. The exterior threaded portion may be formed of left-hand threads or right-hand threads. The exterior threaded portion may be a standard (inch), metric, or other thread. The exterior threaded portion of the body may be an external thread, while the interior threaded portion of the head may be a complementary internal thread. The exterior threaded portion of the body may be opposite the second diameter of the body. The exterior threaded portion may be on the surface of the third cylindrical portion. The exterior threaded portion may be formed during the method for forming a rivet fastener.

The body may include a body hole. The body hole may be a cylindrical hole that extends axially through the entire body. The body hole may contain a shank of a mandrel. The body hole may allow for the mandrel to transfer axial force through the body. The body hole may have a diameter that is equal to or greater than the diameter of the shank of the mandrel.

The fastener may include a head. The head may allow for the separation of the first panel and the second panel when the head is removed from the body. The head may be affixed to the body prior to initial installation of the fastener. The head may constrain the first panel to the second panel when it is affixed to the body. The head may constrain the first panel to the second panel by abutting a surface of the first panel while the opposite surface of the first panel abuts the second panel. The head may be removably affixed to the body. The head may be removed from the body by applying torque to the head to rotate the head relative to the body. The head may be affixed to the body by reversing the direction of torque and rotation. The head may be attached to the body by use of a snap-on feature, spring feature, or a press-fit connection.

The head may include an exterior surface. The exterior surface of the head may be used to apply a torque to the head. The exterior surface may be cylindrical, polygonal, domed, or irregular in shape. The exterior surface may have a hexagonal, a quadrangular, or other polygonal perimeter. The exterior surface may include at least one pair of parallel surfaces for torque input. The exterior surface may have a surface texture. The exterior surface may be knurled, ribbed, or otherwise textured.

The head may include a top portion. The top portion may be part of the exterior surface. The top portion may have a head opening. The head opening may allow for access to an inner surface. The inner surface of the head may include the interior threaded portion of the head. The top portion may be cylindrical, domed, polygonal, or irregular in shape.

The head may include a torque interface. The torque interface may be configured to receive a torque to rotate the head relative to the body. The torque interface may allow for a tool to engage with the head. The torque interface may allow for the tool to apply torque to the head. Torque applied to the head through the torque interface may rotate the head relative to the body. The torque interface may be formed on the exterior surface of the head, extend from the exterior of the head, be formed in an interior surface of the head, or a combination thereof. The exterior surface of the head on which the torque interface is formed may be the perimeter of the head. The torque interface may be hexagonal in shape, such that a 6-point or 12-point socket may be used to turn the head. The torque interface may be square, pentagonal, hexagonal, or any other polygonal shape. The torque interface may be a 12-point, external Torx, or other proprietary external shape.

The torque interface may be a tool slot. The tool slot may be formed on an interior surface of the head. The tool slot may be centrally located through the top portion of the head. The tool slot may only extend into a portion of the depth of the head. The tool slot may concentrically and/or coaxially align with the head opening. The tool slot may have a diameter that is less than, greater than, or equal to the diameter of the head opening. The tool slot may be adjacent to the head opening. The tool slot may abut the head opening. The tool slot may be part of the head opening. The tool slot may be hexagonal in shape, such that a 6-point or 12-point socket bit may be used to turn the head. The tool slot may be square, pentagonal, hexagonal, or any other polygonal shape. The tool slot may be a 12-point, external Torx, or other proprietary external shape.

The head may include an interior threaded portion. The interior threaded portion of the head may allow for the head to be removably affixed to the body. The interior threaded portion may define the head opening. The interior threaded portion of the head may interact with the exterior threaded portion of the body. The interior threaded portion of the head may interact with the exterior threaded portion of the third cylindrical portion of the body. The interior threaded portion of the head may allow for the head to be removed from the body when the head is rotated in one direction relative to the body. The interior threaded portion of the head may allow for the head to be affixed to the body when the head is rotated in an opposite direction relative to the body. The interior threaded portion may be formed of left-hand threads or right-hand threads. The interior threaded portion may be a standard (inch), metric, or other thread. The interior threaded portion of the head may be an internal thread, while the exterior threaded portion of the body may be a complementary external thread. The complementary external thread of the body may be formed during the method for forming a rivet fastener.

The head may include a centering feature. The centering feature may aid with the alignment of the head to the first panel. The centering feature may be a cylindrical protrusion from the head. The centering feature may be formed as a protrusion on the bottom surface of the head and extending towards another portion of the body. The another portion of the body may be the third cylindrical portion. The centering feature may have an outer diameter that is smaller than the first panel hole. The head opening may extend through the centering feature. The interior threaded portion may extend along a portion or the entire length of the longitudinal length of the centering feature. The interior threaded portion may extend along the entire longitudinal length of the head, including the centering feature. The interior threaded portion may not extend through the centering feature. The centering feature may rest upon and/or abut the first cylindrical portion when the head is affixed to the body. The third cylindrical portion may reside within the centering feature when the head is affixed to the body.

The head may include one or more head protrusions. The one or more head protrusions may engage the first panel. The one or more head protrusions may mechanically bite into the material of the first panel to prevent rotation of the head. The one or more head protrusions may be features that extend from the head towards the first panel. The one or more head protrusions may be knurling, ribbing, serrations, or other surface features.

The fastener may include a mandrel. The mandrel may transfer force through the body of the fastener to create the deformed area. The mandrel may be gripped by a tool that generates the force required to create the deformed area. The mandrel may not be required if a clinching, welding, stacking, or other process is used to attach the body to the second panel. The mandrel may break into two pieces after the deformed area is created by applying additional axial force to the mandrel. The mandrel may break into two pieces at a predetermined location that is a break point. The mandrel may have a shank and a mandrel head. The mandrel may be used as the swaging tool during the method for forming a rivet fastener. As such, after the method for forming a rivet fastener, the swaging tool may remain in place within the body hole and become the mandrel.

The mandrel may include a shank. The shank may transfer the force provided by a tool to the mandrel head. The shank may have serrations or other textures on its surface to enhance the tool grip of the shank. The shank may be cylindrical. The shank may have a break point on its surface. The shank may or may not reside within the body hole of the body prior to installation of the fastener. The shank may reside, reside partially, or not reside within the body hole after installation of the fastener.

The mandrel may include a mandrel head. The mandrel head may receive an axial force from the shank, which it exerts on the body of the fastener. The mandrel head may exert force from the shank to the second cylindrical portion of the body. The force exerted by the mandrel head may create the deformed area. After the deformed area is formed, the mandrel head may be retention-fit, friction-fit, the like, or a combination thereof within the body such that the mandrel retains its location within the body when the force is no longer exerted. The mandrel shank may be removably affixed to the mandrel head. The mandrel shank may be removably affixed to the mandrel head by use of a snap-on feature, spring feature, a press-fit connection, or threading.

The mandrel may include a break point. The break point may be a location where the shank breaks into two pieces. The break point may facilitate breaking of the shank when axial force is applied to the shank. The break point may require more force than the creation of the deformed zone to break the shank. The break point may be a groove or other similar area of reduced diameter on the surface of the shank. The break point may act as a stress concentrator.

The fastener may be comprised of one or more fastener materials. The body, mandrel, head, or any combination thereof may be a metal or any alloy thereof. The body, mandrel, head, or any combination thereof may be steel, aluminum, titanium, copper, brass, any alloy thereof, or any combination thereof. The body mandrel, head, or any combination thereof may be a thermoplastic thermoset, or other non-metal material. The fastener may be nylon, polycarbonate, polyethylene, or any other similar plastic. The body, mandrel, head, or any combination thereof may be made of the same materials. The body, mandrel, head, or any combination thereof may be made of different materials.

The rivet fastener may include one or more features as disclosed in U.S. Pat. No. 12,258,987, which is incorporated herein by reference in its entirety for all purposes.

Panel Assembly

The present teachings may relate to a panel assembly. The panel assembly may be created to affix or constrain one panel to one or more other panels. Panel assembly may include a first panel, a second panel, or even additional panels. The panels may be retained together via a fastener according to the present teachings.

The panel assembly may include a first panel. The first panel may be fastened to a second panel. The first panel may be removably fastened to a second panel. The first panel may be a cover. The first panel may partially cover an otherwise inaccessible area. The first panel may need to be removed to access an otherwise inaccessible area. The first panel may need to be replaced if the first panel is damaged or otherwise compromised. The first panel may have a thickness. The first panel may have a length and width that are greater than the thickness of the first panel. The first panel may include a fastening feature. The fastening feature of the first panel may be a first panel hole.

The first panel may include a first panel hole. The first panel hole may allow for the fastener to fasten the first panel to the second panel. The fastener may be inserted into the first panel hole. The first panel hole may contain the first cylindrical portion of the body. The first panel hole may be separated from the fastener. The first panel hole may be a through hole. The first panel hole may have a diameter that is larger than the first diameter of the first cylindrical portion. The first panel hole may be circular, triangular, square, pentagonal, hexagonal, polygonal, or any shape reciprocal to that of the portion of the fastener inserted therethrough.

The panel assembly may include a second panel. The second panel may be fastened to a first panel. The second panel may be removably fastened to a first panel. The second panel may have a cover affixed. The second panel may partially cover an otherwise inaccessible area. The second panel may need to be separated from the first panel to access an otherwise inaccessible area. The second panel may need to be replaced if the second panel is damaged or otherwise compromised. The second panel may have a thickness. The second panel may have a length and width that are greater than the thickness of the second panel. The second panel may include a fastening feature. The fastening feature of the second panel may be a second panel hole. The second panel may include a second panel hole.

The second panel may include a second panel hole. The second panel hole may allow for the fastener to fasten the first panel to the second panel. The fastener may be inserted into the second panel hole. The second panel hole may contain the second cylindrical portion of the body. The second panel hole may not be separated from the fastener after creation of the deformed area. The second panel hole may be a through hole. The second panel hole may have a diameter that is larger than the first diameter. The second panel hole may be circular, triangular, square, pentagonal, hexagonal, polygonal, or any shape reciprocal to that of the portion of the fastener inserted therethrough.

Panels may relate to panels used in the automotive, aerospace, defense, or other industries. Panels may generally provide protection to components or systems on one side of the panel. An opposite side of the panel may be exposed to the environment. A panel assembly may surround components or systems that may need to be serviced. The panel assembly may make components or systems inaccessible. The panel assembly may allow for access to components or systems by the removal of the first panel. The first panel may be temporarily removed by removing one or more heads from one or more fasteners. The first panel may be re-fastened by replacing one or more heads from one or more fasteners.

Panels may relate to panels made of one or more metals, polymers, fabrics, the like, or any combination thereof. Panels may be rigid, flexible, or a combination thereof. Panels may be steel, aluminum, brass, or any alloy thereof. Panels may be carbon fiber, garolite, fiberglass, or other composites. Panels may be polyethylene, polycarbonate, nylon, or other thermoplastics.

The panel assembly may include one or more features as disclosed in U.S. Pat. No. 12,258,987, which is incorporated herein by reference in its entirety for all purposes.

ILLUSTRATIVE EXAMPLES

The following descriptions of the Figures are provided to illustrate the teachings herein, but are not intended to limit the scope thereof. One or more features illustrated or described with respect to one figure may be combined with one or more features illustrated or described with respect to another figure.

FIG. 1 illustrates a front view of a fastener 10. The fastener 10 may be referred to as a rivet fastener. The fastener 10 is in an undeformed state. The fastener 10 includes a body 12. The body 12 extends through a head opening 60 of a head 16. The body 12 is removably affixed to the head 16. Removable attachment is via an interior threaded portion 26 of the head 16 to an exterior threaded portion 27 of the body 12. The head 16 has a centering feature 44 which projects towards the body 12.

The body 12 includes a mandrel 14 therein. The mandrel 14 resides within a body hole 34 in the body 12. The mandrel 14 has a mandrel head 24. The mandrel head 24 is adjacent to and abuts the body 12. The mandrel head 24 abuts the body 12 opposite the head 16. The mandrel 14 includes a shank 15. The shank 15 is located within the body hole 34. The mandrel head 24 is affixed to or integral with the shank 15. The mandrel includes a break point 46 (not shown) at which the mandrel 14 will break into two pieces if sufficient force is applied. The break point 46 is located on the mandrel shank 15.

The body 12 includes a first cylindrical portion 18 and a second cylindrical portion 20. The body 12 may even have a third cylindrical portion 21. The first cylindrical portion 18 has a first diameter D1, the second cylindrical portion 20 has a second diameter D2, and the third cylindrical portion 21 has a third diameter D3. The first diameter D1 is greater than the second diameter D2. The first diameter D1 is greater than the third diameter D3. The third diameter D3 may be equal to or smaller than the second diameter D2. Formed on the first cylindrical portion 18 is a shoulder 22. The shoulder 22 may be defined as the radial plane between the first cylindrical portion 18 and the second cylindrical portion 20. The shoulder 20 is formed by the difference between the first diameter D1 and the second diameter D2.

FIG. 2A illustrates the fastener 10 inserted into a panel assembly 50. The fastener 10 is in an undeformed state. The panel assembly 50 includes a first panel 28 and a second panel 30. The first panel 28 is located on and abuts (e.g., overlaps) the second panel 30. The fastener 10 is shown inserted into a first panel hole 36 of a first panel 28 and a second panel hole 38 of a second panel 30. The second panel hole 38 is smaller in diameter than the first panel hole 36. The first panel hole 36 is larger than the first diameter D1 of the first cylindrical portion 18. The first panel hole 36 is smaller in diameter than the head 16. The second panel hole 38 is larger than the second diameter D2 of the second cylindrical portion 20. The second panel hole 38 is smaller than the first diameter D1 of the first cylindrical portion 18. The second panel 30 is adjacent to and abuts the shoulder 22. Otherwise phased, the first cylindrical portion 18 (e.g., shoulder 22) rests on the second panel 30. The first panel 28 resides between and abuts both the second panel 30 and the head 16. In other words, the first panel 28 is sandwiched between the head 16 and the second panel 30.

FIG. 2B illustrates a cross-section of a fastener 10 in a deformed state and fastened to a panel assembly 50. The second panel 30 is permanently constrained to the body 12 by being compressed between the first cylindrical portion 18 (e.g., shoulder 22) and a deformed area 32. The deformed area 32 is formed when an axial force is applied to the mandrel 14. The mandrel 14 resides within the body hole 34 of the body 12. The mandrel head 24 of the mandrel 14 transfers axial force on the mandrel 14 to the body 12 to permanently deform the body 12 and create the deformed area 32. The mandrel shank 15 includes a break point 46 such that when a greater amount of force is applied to the mandrel 14 than is required for the deformation of the fastener body 12, the shank will break into two pieces at the predetermined break point 46 location.

FIG. 3 illustrates a top view of the head 16. The head 16 has an exterior surface 39. The exterior surface 39 may be a torque interface 40. The torque interface 40 may interact with a tool (not shown). The head has a top portion 62. The top portion 62 of the head 16 has a head opening 60 which allows for access to an inner surface. The inner surface is an interior threaded portion 26.

FIG. 4 illustrates a top view of the head 16. The head 16 has an exterior surface 39. The head has a top portion 62. The top portion 62 of the head 16 includes a tool slot 64. The tool slot 64 may be a torque interface 40. The tool slot may interact with a tool (not shown). The tool slot 64 may be formed as a depression on the top portion 62. It is also feasible that the tool slot 64 is formed as a protrusion. The top portion 62 of the head 16 has a head opening 60 which allows for access to an inner surface, which is an interior threaded portion 26. The tool slot 64 may have a diameter greater than the diameter of the head opening 60. The center of the tool slot 64 may align with the center of the head opening 60.

FIG. 5 illustrates a front view of the head 16. The head 16 has an exterior surface 39. The exterior surface 39 may be a torque interface 40. The torque interface 40 may interact with a tool (not shown). The head 16 has a head opening 60. The head opening 60 extends across a height of the head 16 (e.g., from the top portion 62 to the opposing bottom portion). The head opening 60 allows for access to an inner surface, which is an interior threaded portion 26. The head includes one or more centering features 44. The one or more centering features 44 may be formed as one or more protrusions. The head 16 includes one or more head protrusions 42.

FIG. 6 illustrates a front view of the head 16. The head 16 has an exterior surface 39. The head 16 includes a tool slot 64. The tool slot 64 may be a torque interface 40. The tool slot may interact with a tool (not shown). The head 16 has a head opening 60. The head opening 60 allows for access to an inner surface, which is an interior threaded portion 26. The tool slot 64 may have a diameter greater than the diameter of the head opening 60. The tool slot 64 may align with the head opening 60 along the longitudinal axis of the head 16. The head 16 has a centering feature 44. The centering feature 44 may be formed as a protrusion at a bottom portion of the head 16, opposite the top portion 62. The head 16 has a plurality of head protrusions 42. The head protrusions 42 are formed at the bottom portion of the head 16.

FIGS. 7A-7D illustrate a method for forming the exterior threaded portion 27 on the fastener body 12.

FIG. 7A illustrates a head 16. The head 16 includes a centering feature 44. The centering feature 44 projects from the bottom surface of the head 16. The head 16 includes a head opening 60. The head opening 60 allows access to an interior threaded portion 26. The body 12 includes a body hole 34 extending along its longitudinal axis. Prior to insertion of the body 12 through the head 16, the exterior surface of at least a portion of the body 12 is initially smooth and does not include threads. For example, a portion of the body 12, which is adjacent to the first cylindrical portion 18 (e.g., the third cylindrical portion 21), may have a smooth exterior.

FIG. 7B illustrates the head 16 seated on the body 12. For example, a centering feature 44 may abut with a first cylindrical portion 18. A portion of the body 12 resides within the head 16. A portion of the body 12 may also reside within the centering feature 44. For example, a third cylindrical portion 21 of the body 12 may extend through the head opening 60. The portion of the body 12 (e.g., third cylindrical portion 21) within the head 16 may have a substantially smooth exterior surface prior to and after insertion into the head 16.

FIG. 7C illustrates a swaging tool 70 being inserted into the body 12. The swaging tool 70 is inserted into a body hole 34 of the body 12. For example, the swaging tool 70 is inserted into the body hole 34 of the third cylindrical portion 21. To be inserted into the body hole 34, the swaging tool 70 is also inserted through the head opening 60 of the head 16. The swaging tool 70 may extend into the head opening 60 toward or even into the centering feature 44. The swaging tool 70 may include a helical ridge or ridges 72. The swaging tool 70 exerts a deformation force on the portion of the body 12 that resides within the head 16. The deformation force may be an outward radial force. For example, the deformation force may be generated during the insertion and/or rotation of the swaging tool 70 within the body hole 34. The portion of the body 12 may be the interior surface of the body hole 34, such as within the third cylindrical portion 21. The portion of the body 12 that resides within the head 16 is permanently deformed to be reciprocal to and mate with the internal threaded portion 26 of the head 16. Such deformation forms an exterior threaded portion 27 (not shown) on the portion of the body 12 that resides within the head 16.

FIG. 7D depicts the swaging tool 70 being removed from the body 12. It is possible that the swaging tool 70 is not removed and serves as the mandrel 14 (not shown). For further illustrative purposes, FIG. 7D also shows the body 12 removed from the head 16, exposing the exterior threaded portion 27 of the body 12 formed from the swaging tool 70. The method does not require separation of the head 16 from the body 12 prior to insertion of a mandrel 14. The swaging tool 70 may include one or more protrusions 74. A protrusion 74 may include the helical ridge(s) 72 (as shown in FIG. 7C) or may be one or more individual pointed protrusions 76. The protrusion(s) 74 may extend perpendicularly away from the longitudinal axis of the swaging tool 70 or offset from the longitudinal axis of the swaging tool 70. Removal of the swaging tool 70 may require disengaging (e.g., unthreading, rotation) the swaging tool 70. Removal of the body 12 from the head 16 is provided by disengaging the exterior threaded portion 27 from the interior threaded portion 26, such as by unthreading (e.g., rotation).

Unless otherwise stated, any numerical values recited herein include all values from the lower value to the upper value in increments of one unit if there is a separation of at least 2 units between any lower value and any higher value. As an example, if it is stated that the amount of a component, a property, or a value of a process variable such as, for example, temperature, pressure, time, and the like is, for example, from 1 to 90, preferably from 20 to 80, more preferably from 30 to 70, it is intended that intermediate range values such as (for example, 15 to 85, 22 to 68, 43 to 51, 30 to 32 etc.) are within the teachings of this specification. Likewise, individual intermediate values are also within the present teachings. For values which are less than one, one unit is considered to be 0.0001, 0.001, 0.01, or 0.1 as appropriate. These are only examples of what is specifically intended, and all possible combinations of numerical values between the lowest value and the highest value enumerated are to be considered to be expressly stated in this application in a similar manner.

Unless otherwise stated, all ranges include both endpoints and all numbers between the endpoints. The use of “about” or “approximately” in connection with a range applies to both ends of the range. Thus, “about 20 to 30″ is intended to cover ”about 20 to about 30″, inclusive of at least the specified endpoints.

The terms “generally” or “substantially” to describe angular measurements may mean about +/−10° or less, about +/−5° or less, or even about +/−1° or less. The terms “generally” or “substantially” to describe angular measurements may mean about +/−0.01° or greater, about +/−0.1° or greater, or even about +/−0.5° or greater. The terms “generally” or “substantially” to describe linear measurements, percentages, or ratios may mean about +/−10% or less, about +/−5% or less, or even about +/−1% or less. The terms “generally” or “substantially” to describe linear measurements, percentages, or ratios may mean about +/−0.01% or greater, about +/−0.1% or greater, or even about +/−0.5% or greater.

The disclosures of all articles and references, including patent applications and publications, are incorporated by reference for all purposes. The term “consisting essentially of” to describe a combination shall include the elements, ingredients, components, or steps identified, and such other elements, ingredients, components, or steps that do not materially affect the basic and novel characteristics of the combination. The use of the terms “comprising” or “including” to describe combinations of elements, ingredients, components, or steps herein also contemplates embodiments that consist essentially of, or even consist of the elements, ingredients, components, or steps. Plural elements, ingredients, components, or steps can be provided by a single integrated element, ingredient, component, or step. Alternatively, a single integrated element, ingredient, component, or step might be divided into separate plural elements, ingredients, components, or steps. The disclosure of “a” or “one” to describe an element, ingredient, component, or step is not intended to foreclose additional elements, ingredients, components, or steps.

It is understood that the above description is intended to be illustrative and not restrictive. Many embodiments, as well as many applications besides the examples provided, will be apparent to those of skill in the art upon reading the above description. The scope of the invention should, therefore, be determined not with reference to the above description, but should instead be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. The disclosures of all articles and references, including patent applications and publications, are incorporated by reference for all purposes. The omission in the following claims of any aspect of subject matter that is disclosed herein is not a disclaimer of such subject matter, nor should it be regarded as such that the inventors did not consider such subject matter to be part of the disclosed inventive subject matter.

Claims

1. A method for forming a rivet fastener, the method comprising:

a) placing a portion of a body of the rivet fastener into a head of the rivet fastener such that the portion of the body is located within a head opening of the head; wherein the head opening is defined by an interior threaded portion of the head; wherein the portion of the body which resides within the head is cylindrical and includes a body hole extending along at least a portion of a longitudinal length of the body; wherein the portion of the body which resides within the head opening has an external surface that is substantially smooth; and wherein when the body is inserted into the head, the head opening aligns with the body hole;

b) inserting a swaging tool through the head opening and into the body hole and applying a deformation force onto the portion of the body within the head; wherein to generate the deformation force, the swaging tool exerts an outward radial force to the portion of the body that resides within the head opening; and wherein the deformation force causes the portion of the body that resides within the head to be permanently deformed into an exterior threaded portion reciprocal to and engaged with the interior threaded portion of the head;

c) optionally, removing the swaging tool from the body and the head; and wherein the exterior threaded portion of the body is removably engaged with the interior threaded portion of the head to removably secure the body to the head.

2. The method of claim 1, wherein a mechanical force is applied to the swaging tool such that the swaging tool exerts the outward radial force to the portion of the body that resides within the head.

3. The method of claim 2, wherein the portion of the body which resides within the head is a third cylindrical portion adjacent to a first cylindrical portion and having a smaller diameter than that of the first cylindrical portion.

4. The method of claim 1, wherein the swaging tool has one or more protrusions extending substantially perpendicularly or offset from a longitudinal axis of the swaging tool; and

wherein the one or more protrusions push the portion of the body that resides within the head into the internal threaded portion of the head when a rotational force is applied to the swaging tool.

5. The method of claim 4, wherein the one or more protrusions include a helical ridge that pushes the portion of the body into the internal threaded portion of the head when the rotational force is applied to the swaging tool.

6. The method of claim 5, wherein the swaging tool is a tapered implement with a diameter that increases along the longitudinal axis of the swaging tool.

7. The method of claim 1, wherein the swaging tool is removed from the body and the head, and a mandrel is inserted into the body through the body hole; or the swaging tool remains in place within the body hole and becomes the mandrel.

8. The method of claim 1, wherein the head includes a centering feature formed as a protrusion extending towards the body and configured to align the rivet fastener into a hole of a panel; and

wherein the interior threaded portion extends a longitudinal length of the head and the centering feature.

9. The method of claim 1, wherein the head includes a torque interface configured to receive a torque to rotate the head relative to the body;

wherein the torque interface is formed on an exterior surface and/or an interior surface of the head; and

wherein the exterior surface of the head has a hexagonal, a quadrangular, or other polygonal perimeter.

10. The method of claim 9, wherein the torque interface is formed on the interior surface of the head and is a tool slot centrally located through a top portion of the head;

wherein the tool slot aligns with the head opening along the longitudinal axis of the head; and

wherein the tool slot has a diameter that is greater than the diameter of the head opening.

11. The method of claim 1, wherein the rivet fastener is made of one or more metals; and

wherein, optionally, the one or more metals include steel, aluminum, titanium, copper, brass, any alloy thereof, or any combination thereof.

12. A method for forming a rivet fastener, the method comprising:

a) placing a portion of a body of the rivet fastener into a head opening of a head of the rivet fastener; wherein the head includes a centering feature formed as a protrusion on a bottom surface of the head and extending towards another portion of the body; wherein the head opening is defined by an interior threaded portion of the head; wherein the interior threaded portion extends along an entire longitudinal length of the head, including the centering feature; wherein the portion of the body which resides within the head is cylindrical and includes a body hole extending along at least a portion of a longitudinal length of the body; wherein the portion of the body which resides within the head opening has an external surface that is substantially smooth; and wherein when the body is inserted into the head, the head opening aligns with the body hole;

b) inserting a swaging tool through the head opening and into the body hole and applying a deformation force onto the portion of the body within the head; wherein to generate the deformation force, the swaging tool exerts an outward radial force to the portion of the body that resides within the head opening; and wherein the deformation force causes the portion of the body that resides within the head to be permanently deformed into an exterior threaded portion reciprocal to and engaged with the interior threaded portion of the head;

c) removing the swaging tool from the body and the head; wherein the exterior threaded portion of the body is removably engaged with the interior threaded portion of the head to removably secure the body to the head; and

d) inserting a mandrel into the body hole to form the rivet fastener.

13. The method of claim 12, wherein a mechanical force is applied to the swaging tool such that the swaging tool exerts the outward radial force to the portion of the body that resides within the head.

14. The method of claim 13, wherein the swaging tool has one or more protrusions extending substantially perpendicularly or offset from a longitudinal axis of the swaging tool; and

wherein the one or more protrusions push the portion of the body that resides within the head into the internal threaded portion of the head when a rotational force is applied to the swaging tool.

15. The method of claim 14, wherein the one or more protrusions include a helical ridge that pushes the portion of the body that resides within the head into the internal threaded portion of the head when the rotational force is applied to the swaging tool.

16. The method of claim 14, wherein the swaging tool is a tapered implement with a diameter that increases along a longitudinal axis of the swaging tool.

17. The method of claim 14, wherein the head includes a torque interface configured to receive a torque to rotate the head relative to the body;

wherein the torque interface is formed on an exterior surface and/or an interior surface of the head; and

wherein the exterior surface of the head has a hexagonal, a quadrangular, or other polygonal perimeter.

18. The method of claim 17, wherein the torque interface is formed on the interior surface of the head and is a tool slot centrally located through a top portion of the head;

wherein the tool slot aligns with the head opening along the longitudinal axis of the head; and

wherein the tool slot has a diameter that is greater than the diameter of the head opening.

19. The method of claim 12, wherein the body includes a first cylindrical portion, a second cylindrical portion, and a third cylindrical portion;

wherein the portion of the body that resides within the head is the third cylindrical portion;

wherein the another portion is the first cylindrical portion having a diameter larger than that of the third cylindrical portion, and the centering feature rests upon the another portion;

wherein the first cylindrical portion is located between the second cylindrical portion and the third cylindrical portion; and

wherein the body hole extends through an entire length of the body from the third cylindrical portion through the second cylindrical portion.

20. The method of claim 12, wherein after the rivet fastener is formed, the rivet fastener includes:

a) the body having: i) a first cylindrical portion with a first diameter; ii) a second cylindrical portion with a second diameter, wherein the first diameter is larger than the second diameter such that a shoulder is formed between the first cylindrical portion and the second cylindrical portion; iii) a third cylindrical portion with a third diameter and having the exterior threaded portion; iv) a body hole extending along an axis of the body through the first cylindrical portion, the second cylindrical portion, and the third cylindrical portion;

b) the mandrel having: i) a mandrel shank; and ii) a mandrel head at an end of the mandrel shank opposite the head;

c) the head having: i) a head opening defined by an interior threaded portion; ii) one or more head protrusions on a surface facing toward the mandrel head and configured to embed into a first panel; and iii) the centering feature, which is formed as the protrusion and faces toward the mandrel head, and which is configured to align the fastener with a first panel hole of the first panel;

wherein the mandrel shank at least partially occupies the body hole;

wherein the mandrel head is located outside of the body and opposite the exterior threaded portion of the body; and

wherein the rivet fastener is configured to be deformed from an undeformed state into a deformed state.