last updated 11/01/2018
Total Surface ContactTM Threads (TSCTsTM) are a new genre in physical threaded connections. There are
four threads with patents issued on three. They have inherent properties that resist loosening, fatigue, corrosion, and have been
shown to be over 25% stronger than traditional threads (US Fastener Journal). Their unique characteristic is the
elimination of the clearance space that all other threads have. While traditional threads have 30-35% contact, TSCT's limits are a function
of fabrication. Operationally they should be in the 90 percentiles.
Most of the research has been on the WaveTM Thread with thousands of models engineered, hundreds 3D printed and one 3-axis CNC machined tested. The graph below shows how it is possible for the wave thread to be stronger then a traditional Unified National Course (UNC) thread. The stress is substantially evenly distributed across the threads. That is impossible with the UNC or any other threads.
This WaveTM Thread is designed to evenly distribute stress. In contrast the UNC thread always has high stress on the first
thread and then the capacity to resist drops quickly. That is why nuts are so thin, extra threads add little.
Fantastic claims require fantastic proof and that is available by pressing this FEA data button. There, more Stress Concentation Factor Graphs with different designs and different impact are shown. AND their data can be downloaded for running Finite Element Analysis and other computer simulation software. Downloading this data is only for the purpose of investigating the WaveTM Thread principals, not for commercial use. Commercial applications are not authorized and require a patent license.
Press Download 3D print files of Wave threaded stud, nuts and bolts and standard
UNC 7/8 9 TPI bolts, nut and studs. There is also a combination wave threaded and UNC threaded stud. These are the models used for destructive testing.
Downloading this data is only for the purpose of investigating the WaveTM Thread principals, not for commercial use.
Commercial applications are not authorized and require a patent license.
The 3D print files are are 7/8 nuts, bolts, and studs. The bolts and studs have a 2" shank. The studs will have wave-wave threads; wave-unc threads; and unc-unc threads. One set of destrutive testing pulled the heads of the bolts off but the wave threaded studs were 17.5% stronger then they were supposted to be. It is possible that the wave thread geometry will make weaker materials more useful.
The challenge for any new technology is to get it into the marketplace. The R&D process that has been going on for a decade included
software for high precision threads applied to various parts and 3D printed. Standard theads were also created comparison and testing. This software was
developed so its parts could to be made on any 3D printing or additive process and tested. Then there was a moment of realization that boarded on stupid.
The technology for delivering these parts to the 3D maketplace was already operational. It needs to be packaged.
Press Computer aided 3D parts for more info
There are several types of Total Surface Contact Threads, each with a number of geometric parameters
that enable a degree of engineering precision and control currently unavailable. By utilizing TSCTs, engineers
will be able to make their products safer, cheaper, and do things otherwise impossible prior to TSCTs.
TSCTsTM common characteristic is the elimination of the clearance space that all other threads have. This is mechanically new and its engineering principals have to be determined to be put into application. How much resistance to environmental corrosion or corrosion from unlike metals (AL-CU) in high voltage connections. What are the differences that lack of movement has for hot/cold expansion or load cycling compared with norms. If there no room to absorb vibrational movement, can it transmit it efficiently? Ideally Total Surface ContactTM Threads would seal, in practice fabrication tolerances will require a microscopic layers of sealant. The application would be stronger, more durable pneumatic and hydraulic connection. Eliminating the need for a clearance space opens a range of applications.
Another common TSCTsTM characteristic is all the surfaces engage at the same time and same terminal position. The obseved effect is a tight hold and quick connections. The maximizing of the coefficient of friction has to be reduced to a predictable value for different materials. This would reduce the amount of material in caps to contain gas or liquids in bottles or any container. Soda has to have a pressure release space so the caps would not explode. This is a thread design fuction so the gases can excape around the threads before the cap can come off.
The development of quick connect eletrical, electronic, fiber optic and micro channels will be possible because of this precision positioning. The wires and tubes can be added to a plastic thread mold. Once this part is molded, the mating connection or contact points are machined. The added benifit, if these connections are inherently water tight, they will make industrial/consumer applications more durable.
All TSCTs have morphing surfaces, most are either a cone, concave or convex shape; there are others. This has freedom to design how stresses are distributed. The wave thread above directed stress linearly through the fastener increasing it's tensile strength. Another set have been designed to increase stress in the middle and reduce on the ends. The application is pipe connections and container covers. Press this stress distribution graphs to seel. Another set can allow quick connection with precision things like electrical plugs, position and perpendicularlly align a thousand electronic contacts replacing pins or aligning fiber optic surfaces. Also, morphing threads can fasten multiple parts laterally fasten multiple parts laterally . and around corners.
Some TSCT's can be incorporated as a valve. The plunger, control thread and seat would be replaced with a male threaded plunger and female threaded seat with combined thread control. This is a repeating sealed connection. As a 3D printed replacement component, it could be a fast fix till industrial parts are delivered. 3D printed parts eliminate the need to stockpile and valves could be made on demand.
Three of the Total Surface Contact Threads have US patents; there are others. Their basic principles can be found
in the American Fastener Journal articles
Concentric Thread Principals ,
Wave Thread Principles , and
Conic Thread Geometry 3.5 .
The simplist WaveTM Thread is a stack of expanding circles that follow are spiraling helix. This is the first TSCT type that optimized the substanial even distribution of stress with the unintended effect of increasing its load bearing tensile strength over 25%. It will make stronger aerospace and automotive fasteners. This will replace the USB plug in consumer electronic connections with a quarter turn connection that will not pull out and be water tight. This will replace battery connection with longer lasting high surface contacts that will not loosen and resist corrosion.
The non-circular ConcentricTM Thread is a rotating stack of ANY two dimensional shape, except a circle. Using a circle would make a cone, not a ConcentricTM Thread. The two dimensional shapes can be a square, heart, lizard, or the map of Europe, anything. This will make limitless consumer applications including unique containers. A curved axis concentric thread can screw around a corner reducing the net amount of fastening. The engineering is an application of two intersecting perpendicular planes. Some concentric thread shapes will fasten laterally while engaging linearly, the sides pull into thread. This allows multiple parts to be connected by one engagement. This will be one of the broadest new mechanics chapter.
The Conic TM Thread has the male and female profiles on the same plane at its terminal position. It can be any current thread profile or new geometries. This was the first to eliminate the clearance space. It is another choice of threads to morph, to seal, to connect, to create.
Every discovery has new terms, an expansion of old terms and odd quirks. The limits of every Total Surface ContactdTM Thread design is the female thread, no metaphor intended. It determines how small and tight the internal surface can be fabricated with the external male thread generated automatically. The odd quirk is the concave female shape has a convex shaped mate to show characteristics that otherwise could not be seen.
The work on Total Surface ContactTM Threads has been mostly software development with 3D printing, 3-axis machining and making molds. The future of 3D printing with high resolution will allow a tremendous range of characteristics to be developed, tested and marketed as 3D printable products. Toy robotics with hydraulic and pneumatic components will lead to industrial ones. 3D printed parts are a whole new cauldron of what individuals will be able to make.
Total Surface ContactTM Threads are the invention of Dale E. Van Cor from the American town of Winchester, New Hampshire. He is supported by his wife Wanda. His mathematician is Dr. Ronald Tourgee from Spofford, NH, and his patent attorney is Mike Persson from Laconia, NH. There are two more patents pending and two more in the works.
Dale Van Cor's talent is making his visions into physical parts. Getting applications to market requires developing the engineering tools to predict performance and failure of applications. This will take the resources and talents of others. This is a new genre in physical connections and there is more.
Papers, articles and videos: wavethread.com
Properties of the Van Cor Threads
Markets for total surface contact connections
Licensing, Patents, Fabrication and Meetings