Scalloped nut and method of construction

Claim 2

A sheet metal nut comprising: a tubular barrel portion, a plurality of radially outwardly extending outer lobes extending axially along said barrel portion and defining a outside diameter of said barrel portion, a plurality of radially inwardly extending inner lobes extending axially along said barrel portion circumferentially between said outer lobes, and defining an inside diameter of said barrel portion, said outer lobes defining circumferentially spaced voids between said inner lobes at said inside diameter, an internal lobe thread formed on the radially inner surface of said inner lobes at said inside diameter, said internal lobe thread extending partially circumferentially into the voids defined by the adjacent ones of said outer lobes, said inner lobes having a circumferential length substantially greater than that of said outer lobes, said internal lobe thread having a circumferential arcuate thread length of around 65% to around 70% of the circumference of said inside diameter, said internal lobe thread having a substantially full and generally constant radial depth over substantially all of said circumferential arcuate thread length.

Claim 3

The nut of claim 1 with each said outer lobe having a generally arcuate contour having a first radius and with each said inner lobe having a generally arcuate contour having a second radius which is substantially greater than said first radius.

Claim 4

The nut of claim 1 with each said outer lobe having a generally arcuate contour having a first radius and with each said inner lobe having a generally arcuate contour having a second radius which is substantially greater than said first radius, said second radius being around 1.75 times said first radius.

Claim 5

The nut of claim 1 having a continuous ring portion at one end of said barrel portion and with said ring portion having a continuous internal thread as a continuation of said internal lobe thread.

Claim 6

The nut of claim 1 with at least some of said inner lobes being radially inwardly offset after thread formation to provide a prevailing torque characteristic.

Claim 7

A sheet metal nut comprising: a tubular barrel portion, a plurality of radially outwardly extending outer lobes extending axially along said barrel portion and defining a outside diameter of said barrel portion, a plurality of radially inwardly extending inner lobes extending axially along said barrel portion circumferentially between said outer lobes, and defining an inside diameter of said barrel portion, said outer lobes defining circumferentially spaced voids between said inner lobes at said inside diameter, an internal lobe thread formed on the radially inner surface of said inner lobes at said inside diameter, said internal lobe thread extending partially circumferentially into the voids defined by the adjacent ones of said outer lobes, said internal lobe thread having a circumferential arcuate thread length of around 65% to around 70% of the circumference of said inside diameter, said internal lobe thread having a substantially full and generally constant radial depth over substantially all of said circumferential arcuate thread length.

Claim 8

A sheet metal nut comprising: a tubular barrel portion, a plurality of radially outwardly extending outer lobes extending axially along said barrel portion and defining a outside diameter of said barrel portion, a plurality of radially inwardly extending inner lobes extending axially along said barrel portion circumferentially between said outer lobes, and defining an inside diameter of said barrel portion, said outer lobes defining circumferentially spaced voids between said inner lobes at said inside diameter, an internal lobe thread formed on the radially inner surface of said inner lobes at said inside diameter, said internal lobe thread extending partially circumferentially into the voids defined by the adjacent ones of said outer lobes, said internal lobe thread having a circumferential arcuate thread length of around 65% to around 70% of the circumference of said inside diameter, said internal lobe thread having a substantially full and generally constant radial depth over substantially all of said circumferential arcuate thread length.

Claim 9

A sheet metal nut having an internal thread formed by a form tap for application onto the mating thread of an associated male threaded member, said sheet metal nut comprising: a tubular barrel portion, a plurality of radially outwardly extending outer lobes extending axially along said barrel portion and defining a outside diameter of said barrel portion, a plurality of radially inwardly extending inner lobes extending axially along said barrel portion circumferentially between said outer lobes, and defining an inside diameter of said barrel portion, said outer lobes defining circumferentially spaced voids between said inner lobes at said inside diameter, an internal lobe thread formed on the radially inner surface of said inner lobes at said inside diameter, an internal lobe thread extending partially circumferentially into the voids defined by the adjacent ones of said outer lobes, said internal lobe thread having a circumferential arcuate thread length of around 65% to around 70% of the circumference of said inside diameter, said internal lobe thread formed to be at substantially 100% of the thread volume defined by the form tap and hence having a substantially full and generally constant radial dept over substantially all of said circumferential arcuate thread length.

Claim 10

A sheet metal nut having an internal thread formed by a form tap for application onto the mating thread of an associated male threaded member, said sheet metal nut comprising: a tubular barrel portion, a plurality of radially outwardly extending outer lobes extending axially along said barrel portion and defining a outside diameter of said barrel portion, a plurality of radially inwardly extending inner lobes extending axially along said barrel portion circumferentially between said outer lobes, and defining an inside diameter of said barrel portion, said outer lobes defining circumferentially spaced voids between said inner lobes at said inside diameter, an internal lobe thread formed on the radially inner surface of said inner lobes at said inside diameter, an internal lobe thread extending partially circumferentially into the voids defined by the adjacent ones of said outer lobes, said internal lobe thread having a circumferential arcuate thread length of around 65% to around 70% of the circumference of said inside diameter, said internal lobe thread formed to be at substantially 100% of the thread volume defined by the form tap and hence having a substantially full and generally constant radial dept over substantially all of said circumferential arcuate thread length.

Claim 11

The sheet metal nut of claim 7 with said internal lobe thread having around 90% of the available volume of the mating thread on the associated male threaded member.

Claim 12

A fastening system including: (a) a sheet metal nut member comprising: a tubular barrel portion, a plurality of radially outwardly extending outer lobes extending axially along said barrel portion and defining a outside diameter of said barrel portion, a plurality of radially inwardly extending inner lobes extending axially along said barrel portion circumferentially between said outer lobes, and defining an inside diameter of said barrel portion, said outer lobes defining circumferentially spaced voids between said inner lobes at said inside diameter, an internal lobe thread formed on the radially inner surface of said inner lobes at said inside diameter, said internal lobe thread extending partially circumferentially into the voids defined by the adjacent ones of said outer lobes, said internal lobe thread having a circumferential arcuate thread length of around 65% to around 70% of the circumference of said inside diameter, and (b) a male threaded member having a mating thread for threadable engagement with said internal lobe thread, said internal lobe thread having a substantially full radial depth over substantially all of said circumferential arcuate thread length with said full radial depth being substantially 90% of the available volume of said mating thread on said male threaded member.

Claim 13

A fastening system including: (a) a sheet metal nut member comprising: a tubular barrel portion, a plurality of radially outwardly extending outer lobes extending axially along said barrel portion and defining a outside diameter of said barrel portion, a plurality of radially inwardly extending inner lobes extending axially along said barrel portion circumferentially between said outer lobes, and defining an inside diameter of said barrel portion, said outer lobes defining circumferentially spaced voids between said inner lobes at said inside diameter, an internal lobe thread formed on the radially inner surface of said inner lobes at said inside diameter, said internal lobe thread extending partially circumferentially into the voids defined by the adjacent ones of said outer lobes, said internal lobe thread having a circumferential arcuate thread length of around 65% to around 70% of the circumference of said inside diameter, and (b) a male threaded member having a mating thread for threadable engagement with said internal lobe thread, said internal lobe thread having a substantially full radial depth over substantially all of said circumferential arcuate thread length with said full radial depth being substantially 90% of the available volume of said mating thread on said male threaded member.

Claim 14

The fastening system of claim 9 with said inner lobes of said nut member having a circumferential length substantially greater than that of said outer lobes, and each of said outer lobes of said nut member having a generally arcuate contour having a first radius and with each of said inner lobes having a generally arcuate contour having a second radius which is substantially greater than said first radius.

Claim 15

The fastening system of claim 9 with each of said outer lobes of said nut member having a generally arcuate contour having a first radius and with each of said inner lobes of said nut member having a generally arcuate contour having a second radius which is substantially greater than said first radius, said second radius being around 1.75 times said first radius.

Claim 16

The fastening system of claim 9 with said nut member having a continuous ring portion at one end of said barrel portion and with said ring portion having a continuous internal thread as a continuation of said internal lobe thread.