Tolerance compensating fastener and wing nut therefor

Abstract

An example relates to a wing nut (114) for a tolerance compensating fastener (100) that can cooperate with a threaded fastening element (116). The wing nut (114) has a rigid insert (306) and a body member (300). The rigid insert (306) is formed as a hollow cylindrical body and includes a plurality of retaining elements (308) and a plurality of threads (302) formed on an inner wall of the hollow cylindrical body. A body member (300) surrounds the rigid insert (306), the body member (300) having an opening coaxial with a central longitudinal axis of the rigid insert (306) to create a through hole with the hollow cylindrical body to receive a threaded fastening element (116). Each of the plurality of retaining elements (308) is enclosed by the body member (300) to interlock and be secured in the body member (300).

Description

Background Art

[0001] In general, conventional tolerance compensating fasteners are used to fasten two parts to be connected to each other, wherein tolerance compensation is the process of adjusting small differences or alignments of part sizes during the assembly of two parts. For example, either or both of the two parts may have small differences or tolerances in size, so the two parts may not automatically align during installation or assembly. Conventional tolerance compensating fasteners are used between the two parts so that the conventional tolerance compensating fasteners can accommodate differences, tolerances, and alignments relative to each other. In general, conventional tolerance compensating fasteners may be primarily formed of two parts that may move relative to each other during the assembly of the two parts so that the relative movement between the two parts relative to each other can compensate for tolerances and align the two parts that need to be fastened to each other. After alignment, a screw or other fastening component is inserted through the tolerance compensating fastener to securely connect the two parts. Summary of the invention

[0002] The present subject discloses a tolerance compensating fastener and a wing nut for the same. The tolerance compensating fastener can align two parts to be fastened by the tolerance compensating fastener using a threaded fastening element, and the wing nut can cooperate with the threaded fastening element. The tolerance compensating fastener can include a compensating nut, a floating element, a mounting element, and a wing nut. The compensating nut can have a hollow cylindrical body and an outer wall thereof having a threaded profile. The compensating nut can also have a free end and an insertion end, wherein the insertion end can receive the threaded fastening element, and the free end can be at the distal end of the insertion end. The floating element can be engaged at the free end of the compensating nut. The floating element can have a floating element orifice coaxially aligned with respect to the hollow cylindrical body of the compensating nut, and the floating element can be mounted to one of the two parts. The mounting element can have a mounting element orifice coaxially aligned with the central longitudinal axis of the compensating nut and the floating element orifice of the floating element, wherein the mounting element can be interlocked with the floating element and can be movably mounted to one of the two parts. The compensating nut, the floating element, and the mounting element may be able to collectively exhibit movement with up to six degrees of freedom. The wing nut can be mounted to one of a compensating nut, a floating element, and a mounting element away from the insertion end, and can receive a threaded fastening element. The wing nut can include a rigid insert and a main body component. The rigid insert can be formed to have a hollow cylindrical body having a proximal end and a distal end. The proximal end can be an end of the rigid insert facing one end of the wing nut for receiving the threaded fastening element, and the distal end can be axially opposite to the proximal end. The rigid insert can include a plurality of threads formed on the inner wall of the hollow cylindrical body, and a plurality of retaining elements at the proximal end of the rigid insert. In addition, the main body component can surround the rigid insert. The main body component can have an opening coaxial with the central longitudinal axis of the rigid insert to produce a through hole with the hollow cylindrical body of the rigid insert to receive the threaded fastening element, wherein each of the plurality of retaining elements can be enclosed by the main body component to interlock and be fixed in the main body component. BRIEF DESCRIPTION OF THE DRAWINGS

[0003] The detailed description is provided with reference to the accompanying drawings.It should be noted that the description and drawings are only examples of the subject matter and are not intended to represent the subject matter itself.

[0004] Figure 1A A front view of a tolerance compensating fastener fastening a door handle assembly and a door panel of a vehicle according to an example of the present subject matter is shown.

[0005] Figure 1B A rear view of a tolerance compensating fastener fastening a door handle assembly and a door panel of a vehicle according to an example of the present subject matter is shown.

[0006] Figure 2A A front view of a tolerance compensating fastener according to an example of the present subject matter is shown.

[0007] Figure 2B An isometric view of a tolerance compensating fastener according to an example of the present subject matter is shown.

[0008] Figure 2C An exploded view of a tolerance compensating fastener according to an example of the present subject matter is shown.

[0009] Figure 3A A cross-sectional view of a wing nut in a tolerance compensating fastener according to one example of the present subject matter is shown.

[0010] Figure 3B A cross-sectional view of a tolerance compensating fastener with a screw according to one example of the present subject matter is shown.

[0011] Figure 3C An isometric view of a tolerance compensating fastener according to one example of the present subject matter is shown.

[0012] Figure 3D shows a cross-sectional view of an example according to the present subject matter Figure 3C Bottom cross-sectional view of the tolerance compensating fastener with section plane DD shown in FIG.

[0013] Figure 3E Another example of the present subject matter is shown. Figure 3C Bottom cross-sectional view of the tolerance compensating fastener with section plane DD shown in FIG.

[0014] Figure 4 A cross-sectional view of a wing nut having a flared portion in a rigid insert in a tolerance compensating fastener according to another example of the present subject matter is shown.

[0015] Figure 5 An exploded view of a tolerance compensating fastener including a rigid insert according to another example of the present subject matter is shown.

[0016] Figure 6 A perspective view of a wing nut showing a rigid insert therein is shown according to another example of the present subject matter.

[0017] Figure 7 Shows Figure 6 A perspective view of a rigid insert for a wing nut according to an example of the present subject matter is shown in FIG.

[0018] Figure 8 A method of manufacturing a wing nut according to an example of the present subject matter is shown.

[0019] Fig. 9 A method for assembling a first component and a second component according to an example of the present subject matter is shown.

[0020] Throughout the drawings, the same reference numerals denote similar elements, but may not denote identical elements. The drawings are not necessarily drawn to scale, and the sizes of certain portions may be exaggerated to more clearly illustrate the examples shown. In addition, the drawings provide examples and / or implementations consistent with the description; however, the description is not limited to the examples and / or implementations provided in the drawings. DETAILED DESCRIPTION

[0021] Typically, a vehicle (e.g., a four-wheeled vehicle, a two-wheeled vehicle, etc.) includes various components to be assembled. However, at least some of these components may be manufactured to have dimensional tolerances. For example, a door handle assembly may be assembled with an exterior door panel of a vehicle. In an example, in order to assemble two components of a vehicle together, each of the two components is aligned by aligning the corresponding openings of each of the two components. An opening may be an orifice on the body or surface of a component to be fastened or assembled. An opening is generally a passage that allows access to or connection to the other side from one side of a component in multiple directions. In an example, an opening may have various shapes (e.g., circular, rectangular, or irregular shapes) and is generally designed for a specific purpose, such as allowing access, accommodating fasteners, or enabling passage through other components or materials. The construction of an opening generally involves creating a void in a component by molding, cutting, drilling, or other mechanical or manufacturing processes during manufacturing, depending on the material and design requirements of the component.

[0022] In view of the above, two components of a vehicle are assembled by aligning the corresponding openings of each of the two components and fastening them through the corresponding openings. However, the openings of each of the two components are formed via a stamping process, a forming process or welding, which in turn causes a slight difference in size, i.e., a dimensional tolerance. When fastened together, the dimensional tolerance causes a gap to be created between the two components. Assembling various components of a vehicle with gaps therebetween can lead to inconsistencies during assembly. In this regard, it is necessary to compensate for the tolerances to fill the gaps between the components to assemble the components.

[0023] In some scenarios, the gap between the two components can be filled by using a conventional tolerance compensating fastener preassembled on one of the two components of the vehicle. In addition, a fastening component such as a screw passes through one of the openings in each of the two components via a conventional tolerance compensating fastener. Conventional tolerance compensating fasteners have multiple threads to accommodate fastening components. However, conventional tolerance compensating fasteners only compensate for varying tolerances along the direction of a single axis, or can move freely in one degree of freedom to compensate for tolerances because conventional tolerance compensating fasteners may have limited movement and degrees of freedom. For this reason, it is necessary to assemble multiple conventional tolerance compensating fasteners to compensate for tolerances in different directions or multiple directions. As a result, the entire assembly including multiple conventional tolerance compensating fasteners becomes bulky and costly.

[0024] In addition, the material composition of the components of conventional tolerance compensating fasteners, such as the nut that receives the fastening component, also presents significant challenges. Fastening elements made solely of flexible materials, such as plastic or similar materials, provide the flexibility to accommodate tolerance differences, but lack the strength to withstand high torques during assembly. Such fastening elements are prone to cracking or deforming when considerable forces are applied. In contrast, fastening elements constructed entirely of stronger materials, such as metal, provide the durability required to withstand high torques, but lack the flexibility required to compensate for differences in tolerances and component sizes.

[0025] This challenge between strength and flexibility in material selection creates a need for an improved solution that can effectively combine both properties to address the complex requirements of compensating tolerances while maintaining durability, cost-effectiveness, and ease of assembly.

[0026] The present subject matter discloses examples and aspects that particularly address the above-mentioned problems. In one example, the present subject matter relates to a wing nut that can cooperate with a threaded fastening element and a tolerance compensating fastener to align two parts by compensating for gaps and misalignments between two parts to be fastened. The threaded fastening element can be, for example, a screw, a bolt, etc. The gap can be any misalignment or space between two parts intended to be fastened together. The gap can occur, for example, due to manufacturing tolerances, material differences, assembly problems, or design requirements, and can affect the fit, function, and stability of the assembled parts.

[0027] The tolerance compensating fastener of the present subject matter is designed to have higher strength and durability to withstand greater torque, while also having the flexibility to accommodate wider tolerance differences in different directions. In addition, the tolerance compensating fastener is designed to be cost-effective. The tolerance compensating fastener can be used to fasten together at least two components that may need to compensate for tolerance. For example, but not limited to this, the two components may be a door handle assembly and a door panel of a door assembly of a vehicle. The examples of the present subject matter are not limited to this, and can be applied when fastening any two components of a vehicle, wherein the components may be any two components of a door assembly of a vehicle that require tolerance compensation.

[0028] The wing nut of the present subject matter is designed in a manner so that it can be durable and have sufficient strength to withstand the higher torque received from the threaded fastening element to fasten at least two parts, while also maintaining flexibility to compensate for varying tolerances in different directions. In addition, the wing nut improves fastening efficiency and provides increased resistance to damage, thereby potentially extending its operating life and expanding its applicability in different industries. In other words, the wing nut of the present subject matter is designed in a manner that it can cooperate with the threaded fastening element, wherein the wing nut can be a component of a tolerance compensating fastener that can assist in fastening, and other components of the tolerance compensating fastener can compensate for varying tolerances. However, embodiments of the wing nut of the present subject matter are not limited thereto and can be implemented in various clamps for fastening.

[0029] The wing nut of the present application may include a rigid insert and a body component. The body component may surround the rigid insert and may have an opening coaxial with the central longitudinal axis of the rigid insert to create a through hole with the hollow cylindrical body of the rigid insert to receive a threaded fastening element. In an example, the rigid insert may be a metal insert. In another example, the body component may be a plastic material. The wing nut includes a rigid insert, which may be formed as a hollow cylindrical body with an internal thread, enclosed in a body component typically made of plastic. The rigid insert provides durability and thread strength, while the body component allows for complex geometries and weight reduction.

[0030] The rigid insert of the wing nut may be formed as a hollow cylindrical body having a proximal end and a distal end, wherein the proximal end may be an end of the rigid insert facing the wing nut for receiving an end of the threaded fastening element, and the distal end may be an end axially opposite to the proximal end. The rigid insert may have a plurality of threads and a plurality of retaining elements. The plurality of threads of the rigid insert may be formed on the inner wall of the hollow cylindrical body to receive and lock the threaded fastening element by a plurality of threads. A plurality of retaining elements may be at the proximal end of the rigid insert, wherein each of the plurality of retaining elements is encapsulated by the main body component to interlock and be fixed in the main body component. A plurality of retaining elements may be designed in a manner that the rigid insert is maintained in its original position and remains integrated with the main body component (even in the case where the threaded fastening element applies an opposing force when tightening). The plurality of retaining elements at the proximal end of the rigid insert encapsulated by the main body component ensure that the rigid insert remains firmly interlocked and fixed with the main body component even under high torque.

[0031] According to an example, a technique for manufacturing a wing nut as shown above may include placing a rigid insert in a cavity of a mold. The rigid insert may have a similar construction as stated above, with multiple threads and multiple retaining elements at the proximal end of the rigid insert. In addition, a filler is positioned in the hollow cylindrical body of the rigid insert contained in the mold. Further positioned, an overmolding material is injected around the rigid insert in the mold. The overmolding material may surround the rigid insert, may have a similar construction as stated above, and may form an opening coaxial with the hollow cylindrical body of the rigid insert to create a through hole with the hollow cylindrical body of the rigid insert. The overmolding material is allowed to cool to form a body component around the rigid insert, wherein the multiple retaining elements will interlock and be fixed to the body component. Finally, the wing nut is removed from the mold.

[0032] Through the above examples, the rigid insert can be completely locked in the wing nut together with the plastic product during the overmolding process. In addition, the rigid insert can ensure that the rigid insert is completely locked with the plastic product of the wing nut through the above-mentioned multiple retaining elements, and will not shear or cut the wing nut as more torque is applied to the screw during tightening, and will not shear or cut the wing nut when more torque is applied to the screw during tightening. In this way, the wing nut can withstand more torque. Through these embodiments, the wing of the wing nut can provide a reliable lock with the plastic manufacturing part of the wing nut during the overmolding process, and the rigid insert part can be close to the wing nut and firmly locked with the wing nut, that is, the plastic part is manufactured and matched with the rigid insert. Through the above embodiments, the rigid insert is effectively locked in the wing nut, and will not shear and cut the wing nut as the screw is inserted with a higher torque, and will not shear and cut the wing nut when the screw is inserted with a higher torque.

[0033] The subject wing nut is designed to allow higher torque application than conventional all-plastic wing nuts while maintaining ease of manipulation. This design may reduce material costs compared to all-metal alternatives, providing a balance between strength and economy.

[0034] In addition, the manufacturing technique employs precision insert placement combined with universal overmolding. This technique results in a wing nut that provides excellent torque resistance and weight optimization. Overmolding allows for the creation of complex geometries, thereby enhancing design flexibility beyond what is possible with conventional single-material fasteners. The disclosed technique ensures that the strength of the rigid insert is retained while enabling the formation of complex external shapes customized for specific applications.

[0035] In another example, a wing nut may be implemented in the tolerance compensating fastener of the present subject matter.

[0036] The tolerance compensating fastener can be designed in a way to align two parts so that the tolerance compensating fastener allows movement with up to six degrees of freedom. In this way, movement in all six directions allows two parts (such as a first part and a second part) to be aligned so that misalignment and gaps between the two parts to be fastened can be compensated by the threaded fastening element. The tolerance compensating fastener of the present subject matter can have six degrees of freedom of movement, which allows the tolerance compensating fastener to move in any of the six directions until the first part and the second part are aligned. In this way, since it is designed to have six degrees of freedom, the tolerance compensating fastener of the present subject matter can be moved to align the first part and the second part, in this way, the misalignment between the two parts is corrected, and the gap is also compensated by alignment accordingly. The tolerance compensating fastener may include a compensation nut, a floating element, a mounting element, and a wing nut.

[0037] The compensating nut may be a hollow cylindrical body and have an outer wall having a threaded profile. In addition, the compensating nut may have a free end and an insertion end, wherein the insertion end may receive a threaded fastening element and the free end is distal to the insertion end. A floating element may be engaged at the free end of the compensating nut. The floating element may have a floating element orifice coaxially aligned with respect to the hollow cylindrical body of the compensating nut, and the floating element may be movably mounted to one of the two components. The mounting element may have a mounting element orifice coaxially aligned with the central longitudinal axis of the compensating nut and the floating element orifice of the floating element. The mounting element may be interlocked with the floating element and movably mounted to one of the two components.

[0038] In view of the above-mentioned construction, a tolerance compensating fastener including a compensating nut, a floating element, and a mounting element may be able to be assembled together to be installed on one of the two components as a single unit to form a first subassembly. In order to assemble the two components, a single unit assembly of a tolerance compensating fastener including a compensating nut, a floating element, and a mounting element may be able to exhibit movement with up to six degrees of freedom when receiving a threaded fastening element from the insertion end of the compensating nut. The tolerance compensating fastener may be moved in all 6 directions as needed to align the two components to be fastened, and by aligning, the tolerance compensating fastener may compensate for differences, misalignments, and gaps between the two components. The wing nut may be installed away from the insertion end and receive a threaded fastening element. For the sake of brevity, the wing nut may have a similar construction as shown above and is not repeated here.

[0039] According to an example, in order to align two components by a tolerance compensating fastener as described above, the technology may require aligning the two components, wherein the alignment may include positioning the corresponding apertures of each of the two components relative to each other. In an example, the two components may be any components to be fastened together, such as components of a vehicle. In an example, one of the two components may have a first aperture, and the other of the two components may have a second aperture. In order to align the two components to compensate for misalignment and also fill the gap, the first aperture and the second aperture may have to be coaxially aligned relative to each other. The tolerance compensating fastener may be fastened between the two components in a manner that the compensation nut, the floating element, and the mounting element can be mounted on one of the two components as a single unit, thereby forming a first subassembly. This also includes aligning the first aperture of one of the two components with the through hole of the tolerance compensating fastener, wherein the compensation nut, the floating element, and the mounting element can collectively exhibit movement with up to six degrees of freedom. The through hole can be, for example, a continuous opening or passage that extends completely through the body of the tolerance compensating fastener from one end to the other end, and extends along the central longitudinal axis of the tolerance compensating fastener, and allows the insertion and reception of another fastening element or a material such as a threaded fastening element. The other of the two components can be positioned together with the first subassembly in a manner that the second orifice of the other of the two components is aligned with the first subassembly. In addition, the wing nut is locked with the component of the tolerance compensating fastener of the first subassembly. In an example, the wing nut can be locked by a locking component. In one example, the locking component can be a snap-fit ​​lock, a clip, a latch, a rivet, a clamp, etc. In this way, the other of the two components can be positioned between the wing nut and the first subassembly, that is, between the wing nut and the single unit assembly of the compensation nut, the floating element, and the mounting element. For the sake of simplicity, the wing nut can have a similar construction as shown above, and is not repeated here.

[0040] When assembled, the compensating nut, floating element and mounting element are assembled on one of the two parts as a single unit, and the wing nut is assembled on the opposite side of the single unit, with the other of the two parts sandwiched therebetween. Once the threaded fastening element passes through the insertion end of the compensating nut and correspondingly passes through the floating element and then passes through the mounting element, the single unit mounted on one of the two parts jointly exhibits a movement with up to six degrees of freedom. The tolerance compensating fastener is designed to correct the misalignment between the two parts with up to six degrees of freedom (including both position adjustment and rotation adjustment). This means that the tolerance compensating fastener can compensate for the gap (linear displacement) and angular misalignment between the parts. The six degrees of freedom may include, for example, three translational movements (up / down, left / right, forward / backward) and three rotational movements (pitch, yaw and roll). When the threaded fastening element is inserted, the tolerance compensating fastener with the compensating nut, floating element and mounting element can move together in any combination of these six degrees. This movement allows the tolerance compensating fastener to dynamically adjust its position and orientation to effectively fill the gap and correct the misalignment between the two parts being fastened. Where the problem is a linear offset causing a gap, or an angular misalignment causing the components to tilt relative to each other, a tolerance compensating fastener may have the ability to move in these six degrees of freedom, enabling it to accommodate and ensure proper alignment, contact, and clearance between components. This comprehensive adjustment capability ensures that the fastener can accommodate a variety of manufacturing tolerances and assembly differences, resulting in a secure and properly aligned connection.

[0041] The wing nut finally receives the threaded fastening element and cooperates with the threaded fastening element as it passes through the compensating nut, the floating element, and the mounting element, ultimately tightening and engaging to correct the misalignment and fill the gap between the two components. This configuration allows the two components to be aligned by positioning the corresponding apertures relative to each other. The tolerance compensating fastener can be installed on one component as a single unit, with the other component positioned between the wing nut and the assembly. This design enables the fastener to effectively compensate for misalignments and gaps caused by manufacturing tolerances, material differences, assembly problems, or design requirements, thereby ensuring proper fit, function, and stability of the assembled parts.

[0042] In view of the above arrangement, the tolerance compensating fastener can have the flexibility of compensating tolerance differences in different directions through plastic products, and provide strength to withstand greater torque without breaking through rigid inserts. The tolerance compensating fastener of the subject of the present invention can be designed to be durable, effective and low cost. Through the rigid insert in the wing nut, the tolerance compensating fastener provides the operator with the flexibility of fastening parts with varying torques, because the tolerance adjustment part may be able to withstand torque without breaking. In addition, the multiple threads provided on the wing nut in the tolerance compensating fastener can be consistent and may not be easy to break, because the rigid insert can also provide support for the multiple threads. In addition, the tolerance compensating fastener of the present subject is manufactured to have a main body component and a rigid insert via overmolding, which is more time-saving and cheaper. In addition, the strength of the rigid insert and the flexibility of the tolerance compensating fastener to compensate for varying tolerances in different directions are provided.

[0043] The present subject matter provides a significant technical advancement and solution to solve the problems associated with conventional fastening and tolerance compensation technology. Unlike conventional tolerance compensation fasteners that only compensate for the changing tolerance along the direction of a single axis or can only move freely with one degree of freedom to compensate for the tolerance, the present tolerance compensation fastener design allows movement with up to six degrees of freedom. In other words, the tolerance compensation fastener can move in six directions, and correspondingly, this ability can effectively compensate for misalignment and clearance in multiple directions, thereby eliminating the need for multiple fasteners and reducing component volume and cost. The innovative design of the wing nut including a rigid insert in the main body component solves the contradiction between the strength and flexibility of material selection. This combination provides durability to withstand high torque during assembly while maintaining the necessary flexibility to accommodate manufacturing tolerances and differences in component size. The design of the fastener characterized by the interlocking mechanism between the coaxially aligned orifices and the elements ensures smooth installation and stable positioning. The ability to install the compensation nut, floating element and mounting element as a single unit on a component (where another component is located between the wing nut and the component) provides flexibility in installation and adjustment. By combining the strength of a rigid insert with the flexibility of a host component through an overmolding process, the fasteners achieve a balance between durability and economy. The fasteners’ ability to effectively manage misalignments and fill gaps ensures proper fit, function and stability of assembled parts, potentially enhancing the overall structural performance of the assembled component. Together, these advances address the limitations of conventional tolerance-compensating fasteners, providing a more efficient, cost-effective and versatile solution for managing component assembly challenges across a variety of industries, including automotive manufacturing.

[0044] The present subject matter is further described with reference to the accompanying drawings. Where possible, the same reference numerals are used in the drawings and the following description to refer to the same or similar parts. It should be noted that the description and the accompanying drawings only illustrate the principles of the present subject matter. Therefore, it should be understood that various arrangements that can be designed, although not explicitly described or shown herein, cover the principles of the present subject matter. In addition, all statements describing the principles, aspects and examples of the present subject matter and their specific examples herein are intended to cover their equivalents.

[0045] Figure 1A A front view of a tolerance compensating fastener 100 fastening a door handle assembly 102 and a door panel of a vehicle is shown according to an example of the present subject matter. Figure 1B A rear view of a tolerance compensation fastener 100 for fastening a door handle assembly and a door panel of a vehicle according to an example of the present subject matter is shown. Figure 1A-1B .

[0046] An example of the present subject matter relates to a tolerance compensating fastener 100 that is manufactured by overmolding to have a body component and a rigid insert. The tolerance compensating fastener 100 is designed to be stronger, durable, effective, and less expensive, while having durability to withstand greater torques, while also having the flexibility to accommodate wider tolerance differences. The tolerance compensating fastener 100 can be used to fasten at least two components. In one example, the at least two components can include a frame 106 of a door handle assembly 102 and a reinforcement panel 104 of a door panel of a vehicle. The frame 106 of the door handle assembly 102 can be fastened to the reinforcement panel 104.

[0047] The embodiment of the tolerance compensating fastener 100 of the present subject matter has been shown below as being used to fasten a door assembly of a vehicle, wherein the components to be fastened are, for example, a door handle assembly 102 and a door panel, in which respect the two components may be a frame 106 of the door handle assembly 102 and a reinforcement panel 104 of a door panel of a door assembly of a vehicle. However, the embodiments of the present subject matter are not limited thereto and may be implemented to fasten different components of a vehicle to compensate for varying tolerances. In an example, the two components may be any two panels, any two frames, etc. of a vehicle, an electrical device, an electronic device, a machine, furniture, an industrial equipment, etc. In this example, for the sake of brevity, the components to be fastened may be referred to as a door panel and a door handle assembly of a vehicle, i.e., the components to be fastened.

[0048] like Figure 1A and 1BAs shown in , in order to connect the door handle assembly 102 to the door panel, the frame 106 of the door handle assembly 102 may have to be fastened to the reinforcement panel 104 of the door panel. The tolerance compensating fastener 100 can be preassembled and mounted to the reinforcement panel 104 of the door panel to form a first subassembly. In addition, the frame 106 of the door handle assembly 102 can be positioned in an aligned manner with the first subassembly, and the wing nut can be locked with the first subassembly in a manner that the frame 106 can be accommodated between the tolerance compensating fastener 100. The tolerance compensating fastener 100 may include a compensation nut (not shown), a floating element 110, a mounting element 112, and a wing nut 114, which work together to align the two components to compensate for misalignment and gaps between the two components being fastened (in this example, the reinforcement panel 104 and the frame 106).

[0049] The tolerance compensating fastener 100 can align a reinforcement panel 104 and a door panel of a vehicle. The reinforcement panel 104 and the frame 106 each have an aperture (not shown) respectively, such that the aperture on each panel (frame 106 and reinforcement panel 104) corresponds to a size that effectively accommodates the threaded fastening element 116. Each of the apertures (i.e., the first aperture of the reinforcement panel 104 and the second aperture of the frame 106) can be aligned so that the tolerance compensating fastener 100 can be accommodated therebetween to compensate for misalignment and varying clearances.

[0050] As described above, the compensating nut (not shown), the floating element 110, the mounting element 112, and the wing nut 114 work together to compensate for the gap between the two components being fastened (in this example, the reinforcement panel 104 and the frame 106). The compensating nut may have a hollow cylindrical body with an external threaded profile, and has a free end and an insertion end, wherein the insertion end 202-1 is used to receive the threaded fastening element 116. The threaded fastening element 116 may be a screw, a bolt, etc. The threaded fastening element 116 can fasten the two components.

[0051] The floating element 110 may be engaged at the insertion end of the compensating nut 200 and may have a floating element aperture (not shown) aligned with the central longitudinal axis of the compensating nut. In addition, the mounting element 112 may interlock with the floating element 110 and may correspondingly have a mounting element aperture aligned with the floating element aperture and the central longitudinal axis of the hollow cylindrical body of the compensating nut, which mounting element may also be removably mounted to the reinforcement panel 104 of the door panel. The frame 106 may be positioned between the wing nut 114 and the tolerance compensating fastener (including other components, which may be a single unit assembly of the compensating nut, the floating element 110, and the mounting element), which may be preassembled and mounted on the reinforcement panel 104, as shown. Figure 1A-1BThe threaded fastening element 116 may be inserted through the reinforcement panel 104 toward a second aperture of the frame 106 that houses the door handle assembly 102 to fasten the frame 106 to the reinforcement panel 104 .

[0052] As will be explained in detail, the compensating nut, floating element 110 and mounting element 112 together can move together with up to six degrees of freedom. As will be explained later, as and when the threaded fastening element 116 is inserted into the tolerance compensating fastener 100, the tolerance compensating fastener 100 can compensate for varying tolerances in different directions.

[0053] Figure 2A A front view of a tolerance compensating fastener 100 according to an example of the present subject matter is shown. Figure 2B An isometric view of a tolerance compensating fastener 100 according to an example of the present subject matter is shown. Figure 2C An exploded view of a tolerance compensating fastener 100 according to an example of the present subject matter is shown. For the sake of brevity, the following have been explained in conjunction with each other. Figures 2A-2C .

[0054] As about Figure 1A to 1B As stated, the tolerance compensating fastener 100 may include a compensating nut 200 , a floating element 110 , and a mounting element 112 .

[0055] In an example, the compensation nut 200 of the tolerance compensation fastener 100 may be a hollow cylindrical body 202 having an outer wall with a threaded profile 201. In an example, the threaded profile 201 may be in the shape of a spiral ridge or groove on the outer wall of the compensation nut 200. In one example, the compensation nut 200 may be annular, wherein the threaded profile 201 is in the shape of a plurality of spiral lines on its outer surface, so that the threaded profile 201 may correspond to a corresponding profile (not shown) on the reinforcement panel 104 of the door panel to be fastened. The door panel may have a profile similar to the threaded profile 201 of the compensation nut 200 to achieve variable positioning and secure fastening to compensate for clearance when fastening. The threaded profile 201 allows the compensation nut 200 to adjust its position along its longitudinal axis, thereby compensating for clearance between the components to be fastened.

[0056] The compensating nut 200 may have an insertion end 202-1 and a free end 202-2, wherein the insertion end 202-1 receives a threaded fastening element 116, such as a screw or bolt. For example, in automotive applications, this may help align the door handle assembly 102 with the door panel despite minor manufacturing variations.

[0057] The floating element 110 is engaged at the free end 202-2 of the compensating nut 200. The floating element 110 includes a base portion 204, a floating element orifice 206, a plurality of flexible arms 208, and a plurality of fixed components 210. The floating element orifice 206 may be coaxially aligned with the central longitudinal axis of the compensating nut 200. The base portion 204 may have the floating element orifice 206, and the plurality of flexible arms 208 may arcuately extend from the base portion 204 toward one of the plurality of fixed components 210. Each of the plurality of flexible arms 208 may extend as an arc from the base portion 204 toward one of the plurality of fixed components 210 to form an arc shape. In one example, as Figure 1B As shown in , a plurality of fixing members 210 may be fixedly locked to one of the components, such as the reinforcement panel 104 of the door panel. This allows the base portion 204 and the plurality of flexible arms 208 to float and move around the fixing members 210. In other words, the floating element 110 may have a plurality of fixing members 210 diametrically opposite to each other around the floating element 110, and the plurality of fixing members extend orthogonally from the base portion 204 parallel to the compensation nut 200. Each of the plurality of fixing members 210 may be inserted and assembled in the door panel so that the floating element 110 may float. The floating element 110 may move relative to each of the plurality of fixing members 210. In an example, each of the plurality of fixing members 210 may be a plurality of posts, wherein each of the plurality of posts is diametrically opposite to another of the plurality of posts, and each of the plurality of posts may extend orthogonally from a corresponding flexible arm 208 extending orthogonally therethrough, wherein the corresponding flexible arm 208 is one of the plurality of flexible arms 208 that may correspond to each of the plurality of posts.

[0058] The mounting element 112 cooperates with the floating element 110 and the compensating nut 200. The mounting element 112 has a mounting element aperture 211, a mounting base 212, and a plurality of floating elements 214. The mounting element aperture 211 can be coaxially aligned with the central longitudinal axis of the hollow cylindrical body of the compensating nut 200 and the floating element aperture 206. The mounting element 112 can be interlocked with the floating element 110. In an example, the mounting element 112 can be interlocked with the floating element 110 by a snap-fit ​​mechanism between the mounting base 212 and the base portion 204. In other words, the mounting element 112 and the floating element 110 can be snap-fitted to each other. This in turn allows the mounting base 212 to float corresponding to the base portion 204, and also allows the plurality of floating elements 214 to be movable. The plurality of floating elements 214 can extend orthogonally from the mounting base 212 parallel to the compensating nut 200. The plurality of floating elements 214 may be, for example, a plurality of guides, which may be at least one of a claw shape, a hook shape, a grabber shape, etc. In other words, the mounting element 112 may have a plurality of floating elements 214 diametrically opposed to each other around the mounting element 112 and extending orthogonally from the mounting base 212, wherein the mounting base 212 may be interlocked with the floating element 110 via a snap fit. Figures 2A-2C As shown in , the plurality of floating elements 214 may be flexible and may be designed to have a shape similar to a claw, a grappling hook, etc. Figure 1B As shown in , as will be explained later, multiple floating elements 214 may also be allowed to move around corresponding contours of only the door panel to compensate for varying gaps.

[0059] The wing nut 114 may be the female counterpart of the threaded fastening element 116. The wing nut 114 of the tolerance compensating fastener 100 may not only help the tolerance compensating fastener provide a secure connection point by engaging with the threaded fastening element 116, but when tightened, the wing nut 114 may create a strong and stable joint between the two components to be fastened (i.e., in this example, the reinforcement panel 104 of the door panel and the frame 106 of the door handle assembly 102, but not limited to this). For the sake of brevity, the components to be fastened may be referred to interchangeably as the door panel and door handle assembly of the vehicle, i.e., the components to be fastened. The wing nut 114 creates an interface with the threaded fastening element 116 to allow for precise adjustment of tension and to enable both assembly and disassembly of the connection. As will be referenced later Figure 3A-7As explained in detail, the wing nut 114 is designed in a manner that combines strength and adaptability as it is constructed of a rigid insert (not shown) and a body component (not shown), wherein the rigid insert is designed in a manner that provides the necessary strength and durability to accommodate the applied tensions and forces, and the body component is designed in a manner that provides flexibility to easily adjust and move the two components to align. The construction of the wing nut 114 allows it to withstand higher torques during tightening while receiving the threaded fastening element 116 without failure, while also working in conjunction with other components such as compensating nuts, floating elements, and mounting elements to facilitate multi-directional adjustment. By balancing durability with flexibility, the wing nut 114 plays a vital role in the ability of the tolerance compensating fastener to compensate for manufacturing tolerances and misalignment, thereby ensuring a secure yet adaptable connection between components. FIG. 3A to FIG. 7 The wing nut 114 will be discussed in detail below.

[0060] The tolerance compensating fastener 100 may be initially preassembled into two separate subassemblies. A first subassembly including the compensating nut 200, the floating element 110, and the mounting element 112 may be preassembled on the reinforcement panel 104 of the door panel. The wing nut 114 forms a second subassembly with the frame 106. During assembly, the tolerance compensating fastener is preassembled / installed on the reinforcement panel 104 of the door panel, and the frame 106 of the door handle assembly 102 is positioned between the wing nut 114 and the first subassembly. The frame 106 of the door handle assembly 102 of the vehicle (not shown) may be positioned to align with the first subassembly, and the wing nut 114 may be further locked to the first subassembly. In this way, the frame 106 may be positioned between the wing nut 114 and the tolerance compensating fastener 100, so that the corresponding apertures of the reinforcement panel 104, the through holes of the tolerance compensating fastener 100, and the apertures of the frame 106 are aligned along the threaded fastening element 116, and can then be fastened by the threaded fastening element.

[0061] In other words, each of the panels (i.e., the reinforcement panel 104 and the door panel) may have an orifice. By aligning the through hole of the first orifice and the tolerance compensating fastener, the tolerance compensating fastener 100 may be preassembled and installed on the reinforcement panel 104, thereby forming a first subassembly. After alignment, the frame is positioned to align with the first subassembly so that the second orifice can be aligned. In addition, the wing nut 114 is locked with the first subassembly, and the frame 106 is accommodated therebetween. The tolerance compensating fastener 100 is arranged between the door handle assembly 102 and the door panel, wherein the tolerance compensating fastener 100 has a through hole aligned with the first orifice and the second orifice. The threaded fastening element 116 may be positioned in the through hole, the first orifice and the second orifice to connect the tolerance compensating fastener 100, the door handle assembly 102 and the door panel. The threaded fastening element 116 may be inserted through the reinforcement panel 104 through the tolerance compensating fastener 100 toward the frame 106.

[0062] The threaded fastening element 116 may be inserted and passed through the through hole of the tolerance compensating fastener 100 by applying torque to fasten the reinforcement panel 104 and the frame 106 , and thereby the door handle assembly and the door panel.

[0063] In the component of a single unit of the tolerance compensating fastener mounted on one of the two components (in this example, the reinforcing panel 104), the compensating nut 200 can be preassembled to the reinforcing panel 104, and a plurality of fixing components 210 can be locked in the reinforcing panel 104 and assembled in the reinforcing panel. The compensating nut 200 can be adjusted along its length, i.e., by moving toward the door panel in the direction of insertion of the threaded fastening element 116, or moving away from the direction of insertion of the threaded fastening element 116 into the tolerance compensating fastener 100, to compensate for the varying tolerances. The compensating nut 200 may be able to move and have about 2 degrees of freedom to compensate for the tolerances by moving rotationally and linearly along the same central longitudinal axis as the aperture of the door panel. The movement of the tolerance compensating fastener from six degrees of freedom in at least one direction will align the coupled door panel and door handle assembly. The threaded profile 201 of the compensating nut 200 may allow the distance to be varied, but the movement and distance are controlled as required, because the threaded profile 201 may allow the compensating nut 200 to move to adjust only based on the requirements, not just slide. In other words, when the compensating nut 200 can be rotated to move along its axis to have about 2 degrees of freedom, the gap between the two components (i.e., the frame 106 and the reinforcement panel 104) is allowed to be accurately adjusted. This movement of the compensating nut 200 provides initial tolerance compensation in the direction of the central longitudinal axis extending through the center of the tolerance compensating fastener 100 to align with the direction of insertion and tightening of the threaded fastening element 116. This imaginary line of the central longitudinal axis passes through the center of the compensating nut 200, the floating element 110, the mounting element 112, and the wing nut 114. The threaded profile 201 ensures a secure and stable connection between the tolerance compensating fastener 100 through the compensating nut 200 and one of the two components (i.e., in this case, the reinforcement panel 104 of the door panel), while still allowing controlled adjustment as required during the tightening process.

[0064] Correspondingly, the floating element 110 can adjust and move the base portion 204 and the plurality of flexible arms 208 to move around the plurality of fixed components 210 to have about 4 degrees of freedom due to its floating nature. When the floating element 110 is interlocked with the mounting element 112, the mounting element 112 can also adjust and float the plurality of floating elements 214 to have 4 degrees of freedom and move vertically and laterally to align the two components and compensate for misalignment accordingly due to the plurality of flexible arms 208. The plurality of floating elements 214 can move from four degrees of freedom to correct misalignment between the two components.

[0065] In this manner, the compensating nut 200 may have two degrees of freedom, and the floating element together with the mounting element 112 provide four degrees of freedom, and thus, with each component, the subject tolerance compensating fastener 100 achieves 6 (six) degrees of freedom.

[0066] In view of the above, the tolerance compensating fastener 100 can compensate for varying tolerances in different directions.

[0067] Figure 3A A cross-sectional view of a wing nut 114 in a tolerance compensating fastener 100 is shown according to an example of the present subject matter. Figure 3B A cross-sectional view of a tolerance compensating fastener 100 having a threaded fastening element 116 is shown according to an example of the present subject matter. Figure 3C An isometric view of a tolerance compensating fastener 100 according to an example of the present subject matter is shown. Figure 3D shows a cross-sectional view of an example according to the present subject matter Figure 3C Bottom cross-sectional view of the tolerance compensating fastener 100 with section plane DD shown in FIG. Figure 3E Another example of the present subject matter is shown. Figure 3C Bottom cross-sectional view of the tolerance compensation fastener of the section plane DD shown in FIG. For the sake of simplicity, the Figures 3A-3E .

[0068] also, Figure 4 A cross-sectional view of a wing nut 114 having a flared portion 316 in a rigid insert 306 in a tolerance compensating fastener 100 is shown according to another example of the present subject matter. Figure 5 An exploded view of a tolerance compensating fastener 100 including a rigid insert 306 is shown according to an example of the present subject matter. Figure 6 A perspective view of a wing nut 114 showing a rigid insert 306 therein is shown according to another example of the present subject matter. Figure 7 Shown according to Figure 6 A perspective view of the rigid insert 306 of the wing nut 114 of an example of the present subject matter is shown. For the sake of simplicity, the rigid insert 306 of the wing nut 114 has been combined and Figures 3A-3D Explain together Figure 4-7 .

[0069] In the present subject matter, as also shown above, the wing nut 114 of the tolerance compensating fastener 100 may receive a threaded fastening element 116 while fastening two components, such as, but not limited to, a frame 106 and a reinforcement panel 104 .

[0070] The wing nut 114 may have a rigid insert 306 and a body member 300. Figure 3A, the rigid insert 306 may be formed as a hollow cylindrical body having a proximal end 306-1 and a distal end 306-2, wherein the proximal end 306-1 may be an end of the rigid insert 306 facing toward the wing nut 114 for receiving an end of the threaded fastening element 116, and the distal end 306-2 is axially opposite the proximal end 306-1. The rigid insert 306 may include a plurality of threads 302 and a plurality of retaining elements 308. The plurality of threads 302 may be formed on the inner wall of the hollow cylindrical body. The plurality of retaining elements 308 may be at the proximal end 306-1 of the rigid insert 306. Each of the plurality of retaining elements 308 may help to integrally form the rigid insert 306 in the body component 300. In an example, each of the plurality of retaining elements 308 may have a steep profile at a proximal end 306-1 of the rigid insert 306, wherein each of the plurality of retaining elements 308 is diametrically opposed to one another and has a free retaining end facing a distal end 306-2 of the rigid insert 306. The steep profile of each of the plurality of retaining elements 308 may be configured to maintain the integrity between the rigid insert 306 and the body component 300 even when subjected to opposing forces, thereby enhancing the overall durability and performance of the wing nut 114.

[0071] The body component 300 can be overmolded over the rigid insert 306 such that the body component 300 can enclose the rigid insert 306. In an example, the body component 300 can have an opening 300-1 coaxial with the central longitudinal axis 304 of the rigid insert 306 to create a through hole with the hollow cylindrical body of the rigid insert 306 to receive the threaded fastening element 116. The opening 300-1 can also be the opening of the wing nut 114.

[0072] In an example, the body component 300 may be made of a plastic material and the rigid insert 306 may be made of metal.

[0073] In an example, the plurality of threads 302 on the wing nut 114 of the present subject matter can be uniform throughout, such that each of the plurality of threads 302 can have the same size and can be equidistant from each other to effectively accommodate the threaded fastening element 116. In one example, the plurality of threads 302 can be formed by any one of ACME threads, square threads, and metric threads. The wing nut 114 can have a central longitudinal axis 304, such that the plurality of threads 302 can be on a distal end 306-2 of the central longitudinal axis 304 of the wing nut 114.

[0074] In the example, Figures 3A-3EAs shown in FIG. 1 , the wing nut 114 may include a rigid insert 306 and may be manufactured with the body component 300 by an overmolding process. By overmolding, the rigid insert 306 may provide the required durability and strength through the rigid insert 306 and the flexibility of adjustment in tolerances through the plastic of the wing nut 114. The rigid insert 306 may include a machined metal component fixed into the wing nut 114, i.e., overmolded with the body component 300. The rigid insert 306 of the wing nut 114 may be designed so as to have a plurality of threads 302 in the inner circumference.

[0075] In one example, if Figure 4-7 As shown in , the rigid insert 306 can have a flared portion 316 extending from the threaded portion at the distal end of the rigid insert 306. In an example, the rigid insert 306 can have a flared portion 316 extending from the plurality of threads 302 at the distal end 306-2 of the rigid insert 306, wherein the flared portion 316 can extend radially outward and away from the central longitudinal axis 304. In an example, as shown in FIG. Figure 7 , the flared portion 316 may be designed to thus have a conical shape extending outwardly at the distal end of the rigid insert 306 and away from the central longitudinal axis 304. In other words, the flared portion 316 may have a larger diameter than the remainder of the rigid insert 306. The expanded shape of the flared portion 316 may prove effective during the process of overmolding the body component 300 onto the rigid insert 306, i.e., by preventing the body component 300 from overflowing over the edge of the flared portion 316. In the absence of the flared portion 316, the body component 300 may flow over the edge of the rigid insert 306 and may enter the inner wall of the rigid insert 306 and toward the plurality of threads 302 and may accumulate above the plurality of threads 302, thereby adversely affecting the performance of the wing nut 114 during assembly.

[0076] In addition, the flared portion 316 on the rigid insert 306 is provided with a plurality of notches 318 to accommodate the expansion of the rigid insert 306 at the edge without cracking or damaging the material of the rigid insert 306 when the edge of the rigid insert 306 expands. The plurality of notches 318 may be positioned circumferentially around the edge of the rigid insert 306 at the distal end 306-2 and equidistant relative to each other. In other words, the provision of the notches 318 avoids damage to the rigid insert 306 near the edge of the flared portion 316 formed during the expansion operation at the edge of the flared portion 316 extending away from the plurality of threads 302. In an example, each of the plurality of notches 318 may be equidistant from each other on the edge of the flared portion 316 of the rigid insert 306. However, other designs in which slits are provided and arranged around the edge for the purpose of preventing damage to the edge are also contemplated as part of the present subject matter.

[0077] As described above, the rigid insert 306 may include a plurality of retaining elements 308 at the proximal end of the rigid insert 306, and the plurality of retaining elements may have a steep profile at the proximal end 306-1 of the rigid insert 306. Each of the plurality of retaining elements 308 may be diametrically opposite to each other and have a free retaining end, that is, the end of the profile of each of the plurality of retaining elements 308 may be designed in a manner facing the distal end 306-2 of the rigid insert 306. The steep profile of each of the plurality of retaining elements 308 may be designed in a manner to maintain the integration between the rigid insert 306 and the body component 300 even when subjected to opposing forces. In an example, the steep profile of each of the plurality of retaining elements 308 may be designed in a corrugated shape, a curved shape, a hook shape, an arch shape, etc., wherein the free retaining end always faces the distal end 306-2. In one example, each of the retaining elements 308 may be designed in a manner to extend from the second axial direction toward the first axial direction, and further radially extend from the central longitudinal axis 304. In this example, each of the plurality of retaining elements 308 may extend in radially opposite directions relative to each other. After radially extending from the central longitudinal axis 304, the plurality of retaining elements 308 may extend axially from a first axial direction to a second axial direction. In this example, the first axial direction may be a direction closer to the proximal end, and the second axial direction may be closer to the distal end. The plurality of retaining elements 308 of the wing nut 114 may be designed so that the rigid insert 306 is completely locked together with the plastic product of the wing nut 114 via the plurality of retaining elements 308. In another example, the wing nut 114 may include at least one wing extending along the central longitudinal axis 304 of the wing nut 114. The steep profile may be a complex nonlinear shape of each of the plurality of retaining elements 308 to enhance the integration and locking of the rigid insert 306 within the body component 300 of the wing nut 114. These retaining elements 308 are located at the proximal end 306-1 of the rigid insert 306 and feature a complex geometry, which may include, without limitation, a curved, hooked, arched, corrugated, or undulating surface. This complex profile increases the surface area and creates a mechanical interlock between the rigid insert 306 and the body component 300. Each of the plurality of retaining elements 308 has a free retaining end facing the distal end 306-2 of the rigid insert 306, allowing them to resist forces that pull the insert out of the body component 300. This design ensures that the rigid insert 306 remains securely interlocked and fixed within the body component 300 even when subjected to high torque or opposing forces during tightening. Thus, the steep profile prevents the rigid insert 306 from shearing or cutting through the body component 300.

[0078] In the example, Figure 3BAs shown in FIG. 1 , each of the plurality of retaining elements 308 of the rigid insert 306 may be connected to a respective side of the plurality of threads 302 to form a thread guide 310. In an example, in an embodiment where the rigid insert 306 may have a flared portion 316, a thread guide 310 may also be provided.

[0079] When each of the plurality of retaining elements 308 extends in radially opposite directions, each of the plurality of retaining elements 308 may be connected to a closer side of the plurality of threads 302 to form a thread guide 310 at each side of the plurality of threads 302. The thread guide 310 may be a part of the rigid insert 306. The distance between each of the thread guides 310 of at least two thread guides at each side of the plurality of threads 302 on the inner wall of the rigid insert 306 may be smaller than the distance between the plurality of threads 302 on each side of the inner wall. The thread guide 310 may guide the threaded fastening element 116 toward the plurality of threads 302 for tightening, and torque is applied to the threaded fastening element when inserted into the tolerance compensating fastener 100. The composition of the thread guide 310 may be metal, and therefore, the thread guide 310 may be able to withstand a larger torque, and may be designed such that the thread guide 310 may be able to easily guide and direct the course of the screw toward the plurality of threads 302 for effective tightening.

[0080] In order to effectively lock the rigid insert 306 to be surrounded by the body component 300 in the wing nut 114, a mold (not shown) can be designed, which can have at least two retainers (not shown) to hold the rigid insert 306 while the body component 300 can be overmolded thereon, such as Figure 3D As shown in . In this way, the retainer can cause a corresponding imprint 312 to be formed on the main body part 300. Each of the two retainers in the example is arranged on at least two opposite sides of the mold, so that each of the two retainers is diagonally opposite to each other. During the overmolding process, the mold can retain the rigid insert 306 by each of the two retainers, thereby ensuring that any rotational movement or lateral movement of the rigid insert 306 is prevented when overmolding the main body part 300 to form the wing nut 114. In another example, the mold can be designed to have at least four retainers. Each of the four retainers can be arranged on one of the four sides of the mold, so that each of the four retainers is diagonally opposite to each other. In this way, as Figure 3E, the retainers may cause a corresponding imprint 312 to be formed on the body component 300. During the overmolding process, the mold may retain the rigid insert 306 via each of the two retainers, thereby ensuring that any rotational or lateral movement of the rigid insert 306 is prevented when the plastic is overmolded to form the wing nut 114. This in turn allows the rigid insert 306 to be effectively molded into the plastic of the wing nut 114 and locked thereto.

[0081] By the above example, the rigid insert 306 can be completely locked in the wing nut 114 together with the body part 300 during the overmolding process. In addition, by the above-mentioned wings, the rigid insert 306 can ensure that the rigid insert 306 is completely locked with the body part 300 of the wing nut 114, and will not shear or cut off the wing nut 114 as the threaded fastening element 116 applies more torque when tightening, and will not shear or cut off the wing nut when the threaded fastening element applies more torque when tightening. In this way, the wing nut 114 can withstand more torque. By these embodiments, each of the multiple retaining elements 308 of the wing nut 114 can provide a reliable lock with the plastic-made portion of the wing nut 114, and through the overmolding process, the rigid insert 306 portion can be close to the wing nut 114 and firmly locked with the wing nut, that is, the body part 300 is integrated and matched with the rigid insert 306. By the above-described embodiment, the rigid insert 306 is effectively locked into the wing nut and does not shear and cut the wing nut 114 as the screw is inserted at a higher torque.

[0082] In view of the above arrangement, the tolerance compensating fastener 100 can have the flexibility of compensating tolerance differences in different directions and multiple directions through plastic products, and provide strength to withstand greater torque without breaking through the rigid insert 306. The tolerance compensating fastener 100 of the subject matter of the present invention can be designed to be durable, effective and low cost.

[0083] In view of the above arrangement, the tolerance compensating fastener 100 can be designed to be durable, effective and low cost. Through the rigid insert 306 in the wing nut 114, the tolerance compensating fastener 100 provides the operator with the flexibility of fastening the component with a varying torque, because the tolerance adjustment component may be able to withstand the torque without breaking. In addition, the plurality of threads 302 disposed on the wing nut 114 in the tolerance compensating fastener 100 can be consistent and may not be easily broken because the rigid insert 306 can also provide support for the plurality of threads 302. In addition, the tolerance compensating fastener 100 is manufactured via overmolding to have a body component 300 and a rigid insert 306, which is more time-saving and cheaper. In addition, the strength of the rigid insert 306 and the flexibility of the tolerance compensating fastener 100 are provided to compensate for varying tolerances in different directions.

[0084] Figure 8 An illustration of a method 800 of manufacturing a wing nut according to an example of the present subject matter is provided. The order in which the method is described is not intended to be construed as a limitation, and any number of the described method blocks can be combined in any order to implement the method, or an alternate method.

[0085] It is also understood that the manufactured wing nut can be as described above with reference to Figure 1A-7 The illustrated wing nut 114. Correspondingly, the rigid insert may correspond to the reference Figure 3A-7 The rigid insert 306 shown, and the main body component may correspond to the reference Figure 3A-7 The main body component 300 is shown.

[0086] At block 802, a rigid insert may be placed in a cavity of a mold, wherein the rigid insert may be formed to have a hollow cylindrical body having a proximal end and a distal end axially opposite the proximal end. The rigid insert may include a plurality of threads formed on the inner wall of the hollow cylindrical body, and a plurality of retaining elements at the proximal end. The plurality of threads may correspond to the plurality of threads as described above, and the plurality of retaining elements may correspond to the plurality of retaining elements 308 as described above. In addition, the mold as also shown above may be any mold whose cavity may correspond to the size of the threaded fastening element 116.

[0087] At block 804, a filler may be positioned in the hollow cylindrical body of the rigid insert placed in the mold. The filler may simply be a filler component to block any ingress into the rigid insert through the proximal end. In this way, the overmolding material does not pass through the proximal end of the rigid insert into the inner wall of the rigid insert and damage the thread guide or threads.

[0088] At block 806, an overmolding material may be injected around the rigid insert in the mold. The overmolding material may surround the rigid insert and may form an opening coaxial with the hollow cylindrical body of the rigid insert to create a through hole with the hollow cylindrical body of the rigid insert. The opening may correspond to the opening 300-1 described above, and the central longitudinal axis may correspond to the central longitudinal axis 304 described above. The overmolding material is made of plastic and the rigid insert is made of metal.

[0089] At block 808, the overmolding material may be allowed to cool to form a body component around the rigid insert, wherein the plurality of retaining elements will interlock and secure to the body component. The body component poured around the rigid insert in the mold may be allowed to cool to effectively encapsulate the rigid insert and form a wing nut.

[0090] At block 810, the wing nut may be removed from the mold. This may be done after the wing nut has been manufactured.

[0091] Fig. 9 An illustration of a method 900 of assembling a first component and a second component according to an example of the present subject matter is provided. The order in which the method is described is not intended to be construed as a limitation, and any number of the described method blocks can be combined in any order to implement the method, or an alternate method.

[0092] In one example, the first component and the second component may be any components that may need to be fastened to each other. In an example, and in view of the views shown in the above figures, the first component and the second component may be a door panel and a door handle assembly 102. The first component and the second component as described above may be any components, and the embodiments are not limited thereto. The tolerance compensation fastener may be as described above with reference to Figure 1A-7 A tolerance compensating fastener 100 is shown.

[0093] At box 902, the tolerance compensating fastener 100 can be installed on a first component (which can be a door panel in view of the example shown above) (not shown) to form a first subassembly. The tolerance compensating fastener can have a through hole, and the first component can have a first orifice, and wherein the installation includes aligning the first orifice with the through hole. The first subassembly can be formed by preassembling the components of the tolerance compensating fastener (i.e., the compensating nut, the floating element, and the mounting element) as a single unit on the first component. In an example, the compensating nut can be a hollow cylindrical body and can have an outer wall with a threaded profile. The compensating nut can have an insertion end, and the free end can be distal to the insertion end. The floating element can be engaged at the free end of the compensating nut. The floating element can have a floating element orifice coaxially aligned with respect to the central longitudinal axis of the hollow cylindrical body of the compensating nut. The mounting element can have a mounting element orifice coaxially aligned with the central longitudinal axis of the compensating nut and the floating element orifice of the floating element. The mounting element can be interlocked with the floating element. The hollow cylindrical body of the compensating nut, the floating element orifice, and the mounting element orifice are aligned to form a through hole, wherein the base portion of the floating element can be locked together with the mounting base by a snap fit. As a result, any movement of the floating element can cause the mounting element to float and move. The installation also includes aligning the first orifice with the through hole of the tolerance compensating fastener, wherein the compensating nut, the floating element, and the mounting element are able to collectively exhibit movement with up to six degrees of freedom. The hollow cylindrical body of the compensating nut, the floating element orifice, and the mounting element orifice are aligned to form a through hole. The through hole of the tolerance compensating fastener can be a continuous opening or passage extending completely through the body of the tolerance compensating fastener from one end to the other. The through hole can be an opening that can extend along the central longitudinal axis of the tolerance compensating fastener and allow the insertion and reception of another fastening element or material such as a threaded fastening element. It can also be understood that the tolerance compensating fastener and its components shown in this article can correspond to the above referenced Figure 1A-7 The tolerance compensating fastener 100 and its components are illustrated. It is also understood that the threaded fastening element corresponds to the threaded fastening element as described above with reference to Figure 1A-7 The threaded fastening element 116 shown herein is illustrated.

[0094] At block 904 , the second component may be positioned with the first subassembly, where the positioning may include aligning a second aperture of the second component with a through hole of the tolerance compensating fastener and a first aperture of the first component.

[0095] At frame 906, the wing nut of the tolerance compensating fastener can be locked with the tolerance compensating fastener. The wing nut may include a rigid insert and a body component. The rigid insert is formed as a hollow cylindrical body having a proximal end and a distal end, the proximal end being one end of the rigid insert facing the wing nut for receiving one end of the threaded fastening element, and the distal end being axially opposite to the proximal end. The rigid insert may include a plurality of threads and a plurality of retaining elements. The plurality of threads may be formed on the inner wall of the hollow cylindrical body. In addition, a plurality of retaining elements may be at the proximal end of the rigid insert. In addition, the body component may surround the rigid insert and may have an opening coaxial with the central longitudinal axis of the rigid insert to produce a through hole with the hollow cylindrical body of the rigid insert to receive the threaded fastening element. In addition, each of the plurality of retaining elements may be enclosed by the body component to interlock and be fixed in the body component 300. At frame 906, locking includes clamping the second component between the wing nut and the first subassembly. Locking the wing nut with the first subassembly may position the second component between the wing nut and the first subassembly, wherein the wing nut and the second component may form a second subassembly.

[0096] At box 908, a threaded fastening element may be inserted from a first aperture of the first component, through a through hole of the tolerance compensating fastener, a second aperture of the second component, and into an opening in the wing nut to assemble the first component and the second component. By inserting the threaded fastening element, the tolerance compensating fastener may be moved in at least one direction from six (6) degrees of freedom to correct misalignment and gaps and any differences between the first component and the second component. The tolerance compensating fastener is designed to correct misalignment between the two components with up to six degrees of freedom (including both positional and rotational adjustments). This means that the tolerance compensating fastener can compensate for gaps (linear displacements) as well as angular misalignments between the components. The six degrees of freedom may include, for example, three translational movements (up / down, left / right, forward / backward) and three rotational movements (pitch, yaw, and roll). When the threaded fastening element is inserted, the tolerance compensating fastener with the compensating nut, floating element, and mounting element may move together in any combination of these six degrees. This movement allows the tolerance compensating fastener to dynamically adjust its position and orientation to effectively fill the gap and correct the misalignment between the two components being fastened. Where the problem is a linear offset causing a gap, or an angular misalignment causing the components to tilt relative to each other, a tolerance compensating fastener may have the ability to move in these six degrees of freedom, enabling it to accommodate and ensure proper alignment, contact, and clearance between components. This comprehensive adjustment capability ensures that the fastener can accommodate a variety of manufacturing tolerances and assembly differences, resulting in a secure and properly aligned connection.

[0097] Although the example of the wing nut 114 of the tolerance compensating fastener 100 has been described in language specific to structural features and / or methods, it should be understood that the appended claims are not limited to the specific features described. Instead, the specific features are disclosed as examples of the tolerance compensating fastener 100.

Claims

1. A wing nut (114) cooperable with a threaded fastening element (116), the wing nut (114) comprising: A rigid insert (306) formed with a hollow cylindrical body having a proximal end (306-1) and a distal end (306-2), the proximal end (306-1) being an end of the rigid insert (306) facing toward the wing nut (114) for receiving an end of the threaded fastening element (116), and the distal end (306-2) being axially opposite to the proximal end (306-1), the rigid insert (306) comprising: a plurality of threads (302) formed on the inner wall of the hollow cylindrical body, and a plurality of retaining elements (308) at a proximal end (306-1) of the rigid insert (306); and a body member (300) surrounding the rigid insert (306), the body member (300) having an opening coaxial with a central longitudinal axis of the rigid insert (306) to create a through hole with the hollow cylindrical body of the rigid insert (306) to receive the threaded fastening element (116); Each of the plurality of retaining elements (308) is enclosed by the body component (300) so as to be interlocked and fixed in the body component (300).

2. The wing nut (114) of claim 1, wherein the body component (300) is made of a plastic material and the rigid insert (306) is made of metal.

3. The wing nut (114) of claim 1, wherein the plurality of threads (302) are formed by any one of ACME threads, square threads, and metric threads.

4. The wing nut (114) of claim 1, wherein the rigid insert (306) has a flared portion (316) extending from the plurality of threads (302) at a distal end (306-2) of the rigid insert (306), wherein the flared portion (316) extends radially outward and away from the central longitudinal axis.

5. The wing nut (114) of claim 4, wherein the flared portion (316) includes a plurality of notches (318) positioned circumferentially around an edge of the rigid insert (306) at the distal end (306-2) and equidistant relative to one another.

6. The wing nut (114) according to claim 1, wherein each of the plurality of retaining elements (308) has a steep profile at the proximal end (306-1) of the rigid insert (306), wherein each of the plurality of retaining elements (308) is diametrically opposed to each other and has a free retaining end facing the distal end (306-2) of the rigid insert (306), wherein the steep profile of each of the plurality of retaining elements (308) is configured to maintain the integrity between the rigid insert (306) and the main body (300) even when subjected to opposing forces.

7. A tolerance compensating fastener (100) for aligning two components to be fastened by the tolerance compensating fastener using a threaded fastening element (116), the tolerance compensating fastener (100) comprising: A compensating nut (200), the compensating nut having a hollow cylindrical body, the outer wall of the compensating nut having a threaded profile (201), the compensating nut (200) having a free end (202-2) and an insertion end (202-1), wherein the insertion end (202-1) will receive the threaded fastening element (116), and the free end (202-2) is distal to the insertion end (202-1); a floating element (110) engaged at a free end (202-2) of the compensating nut (200), the floating element (110) comprising a floating element orifice (206) coaxially aligned with respect to the hollow cylindrical body of the compensating nut (200), the floating element (110) being mountable to one of the two components; a mounting element (112) having a mounting element aperture (211) coaxially aligned with a central longitudinal axis of the compensating nut (200) and a floating element aperture (206) of the floating element (110), wherein the mounting element (112) is interlocked with the floating element (110) and movably mounted to one of the two components, wherein the compensating nut (200), the floating element (110) and the mounting element (112) are collectively capable of exhibiting movement having up to six degrees of freedom; and A wing nut (114) which can be mounted to one of the compensating nut (200), the floating element (110) and the mounting element (112) away from the insertion end (202-1) and receives the threaded fastening element (116), the wing nut (114) comprising: A rigid insert (306) formed with a hollow cylindrical body having a proximal end (306-1) and a distal end (306-2), the proximal end (306-1) being an end of the rigid insert (306) facing toward the wing nut (114) for receiving an end of the threaded fastening element (116), and the distal end (306-2) being axially opposite to the proximal end (306-1), the rigid insert (306) comprising: a plurality of threads (302) formed on an inner wall of the hollow cylindrical body; and a plurality of retaining elements (308) at a proximal end (306-1) of the rigid insert (306); and a body member (300) surrounding the rigid insert (306), the body member (300) having an opening coaxial with a central longitudinal axis of the rigid insert (306) to create a through hole with the hollow cylindrical body of the rigid insert (306) to receive the threaded fastening element (116); Each of the plurality of retaining elements (308) is enclosed by the body component (300) so as to be interlocked and fixed in the body component (300).

8. The tolerance compensating fastener (100) according to claim 7, wherein the mounting element (112) and the floating element (110) are snap-fitted to each other.

9. A tolerance compensating fastener (100) according to claim 7, wherein the floating element (110) includes a plurality of flexible arms (208), a plurality of fixed parts (210) and a base portion (204), wherein the base portion (204) includes the floating element orifice (206), and wherein each of the plurality of flexible arms (208) extends arched from the base portion (204) toward each of the plurality of fixed parts (210), and wherein each of the plurality of fixed parts (210) is configured to be fixedly locked on one of the two parts, and each of the plurality of flexible arms (208) is configured to float around each of the plurality of fixed parts (210).

10. The tolerance compensating fastener (100) of claim 9, wherein the plurality of fixing components (210) include a plurality of posts, wherein each of the plurality of posts is diametrically opposed to another of the plurality of posts, and each of the plurality of posts extends orthogonally from a corresponding flexible arm (208).

11. The tolerance compensating fastener (100) according to claim 7, wherein the mounting element (112) comprises a mounting base (212) and a plurality of floating elements (214), wherein the mounting element opening (211) is on the mounting base (212), and wherein each of the plurality of floating elements (214) is diametrically opposed to each other around the mounting element (112) and extends orthogonally from the mounting base parallel to the compensating nut (200).

12. The tolerance compensating fastener (100) of claim 7, wherein each of the plurality of floating elements (214) is at least one of a claw shape, a hook shape, and a grapnel shape.

13. The tolerance compensating fastener (100) of claim 7, wherein the body component (300) is made of a plastic material and the rigid insert (306) is made of metal.

14. The tolerance compensating fastener (100) according to claim 7, wherein the plurality of threads (302) of the wing nut (114) are formed of any one of ACME threads, square threads, and metric threads.

15. The tolerance compensating fastener (100) according to claim 7, wherein the rigid insert (306) has a flared portion (316) extending from the plurality of threads (302) at a distal end (306-2) of the rigid insert (306), wherein the flared portion (316) extends radially outward and away from the central longitudinal axis.

16. The tolerance compensating fastener (100) of claim 15, wherein the flared portion (316) includes a plurality of notches (318) positioned circumferentially around an edge of the rigid insert (306) at the distal end (306-2) and equidistant relative to one another.

17. A tolerance compensating fastener (100) according to claim 15, wherein each of the plurality of retaining elements (308) has a steep profile at the proximal end (306-1) of the rigid insert (306), wherein each of the plurality of retaining elements (308) is diametrically opposed to each other and has a free retaining end facing the distal end (306-2) of the rigid insert (306), wherein the steep profile of the retaining element is configured to maintain the integrity between the rigid insert (306) and the main body (300) even when subjected to opposing forces.

18. A door assembly for a vehicle, wherein the door assembly comprises: A door handle assembly (102) having a frame (106) and a first aperture; a door panel having a reinforcement panel (104) and a second aperture aligned with the first aperture; A tolerance compensating fastener (100) according to any one of claims 7 to 17, the tolerance compensating fastener being disposed between the door handle assembly (102) and the door panel, the tolerance compensating fastener (100) comprising a through hole aligned with the first aperture and the second aperture; and A threaded fastening element is positioned in the through hole, the first aperture and the second aperture to couple the tolerance compensating fastener (100), the door handle assembly (102) and the door panel, wherein movement of the tolerance compensating fastener in at least one direction from six degrees of freedom will align the door panel and the door handle assembly (102).

19. A method (800) for manufacturing a wing nut (114), wherein the method comprises: A rigid insert (306) is placed in the cavity of the mold, wherein the rigid insert (306) is formed to have a hollow cylindrical body having a proximal end (306-1) and a distal end (306-2) axially opposite the proximal end (306-1), the rigid insert (306) comprising: a plurality of threads (302) formed on an inner wall of the hollow cylindrical body; and a plurality of retaining elements (308) at the proximal end (306-1); positioning a filler material within a hollow cylindrical body of a rigid insert (306) placed in the mold; injecting an overmolding material around the rigid insert (306) in the mold, wherein the overmolding material surrounds the rigid insert (306) and forms an opening coaxial with the hollow cylindrical body of the rigid insert (306) to create a through hole with the hollow cylindrical body of the rigid insert (306); allowing the overmold material to cool to form a body component (300) around the rigid insert (306), wherein the plurality of retaining elements (308) will interlock and be secured to the body component (300); and The wing nut (114) is removed from the mold.

20. The method (800) of claim 19, wherein placing the rigid insert (306) comprises retaining the rigid insert (306) using a plurality of retainers of the mold prior to injecting the overmolding material.

21. The method (800) of claim 19, wherein the overmolding material is injected in the mold around the rigid insert, wherein the overmolding material is made of plastic and the rigid insert is made of metal.

22. A method (900) for assembling a first component and a second component, the method comprising: A tolerance compensating fastener (100) is mounted on the first component to form a first subassembly, wherein the tolerance compensating fastener (100) has a through hole, and the first component has a first orifice, and wherein the mounting includes aligning the first orifice with the through hole, the tolerance compensating fastener (100) includes a compensating nut (200), a floating element (110), and a mounting element (112), the compensating nut (200) having a hollow cylindrical body and an outer wall having a threaded profile (201), the compensating nut (200) having an insertion end (202-1) and a free end (202-2) distal to the insertion end (202-1), the floating element (110) being engaged at the free end (202-2) of the compensating nut (200), and including a relative a floating element orifice (206) coaxially aligned with a central longitudinal axis of the compensating nut (200), and the mounting element (112) having a mounting element orifice (211) coaxially aligned with a central longitudinal axis of the compensating nut (200) and the floating element orifice (206) of the floating element (110), wherein the hollow cylindrical body of the compensating nut (200), the floating element orifice (206) and the mounting element orifice (211) are aligned to form the through hole in the tolerance compensating fastener (100), and wherein the mounting element (112) is interlocked with the floating element (110), the compensating nut (200), the floating element (110) and the mounting element (112) are capable of collectively exhibiting movement with up to six degrees of freedom; Positioning the second component at the first subassembly, wherein the positioning includes aligning a second aperture of the second component with a through hole of the tolerance compensating fastener (100) and a first aperture of the first component; The invention relates to a method for locking a wing nut (114) of the tolerance compensating fastener (100) with the tolerance compensating fastener, wherein the wing nut (114) comprises a rigid insert (306) and a body part (300), wherein the rigid insert (306) is formed as a hollow cylindrical body, the hollow cylindrical body having a proximal end (306-1) and a distal end (306-2) axially opposite to the proximal end (306-1), wherein the rigid insert (306) comprises a plurality of threads (302) formed on the inner wall of the hollow cylindrical body; and a threaded portion (302) at the proximal end (306-1) of the rigid insert (306). a plurality of retaining elements (308); and wherein the body component (300) surrounds the rigid insert (306), the body component (300) having an opening coaxial with a central longitudinal axis of the rigid insert (306) to create a through hole with the hollow cylindrical body of the rigid insert (306) to receive a threaded fastening element (116); and wherein each of the plurality of retaining elements (308) is enclosed by the body component (300) to interlock and be secured in the body component (300), wherein locking comprises clamping the second component between the wing nut and the first subassembly; The threaded fastening element is inserted from the first aperture of the first component, through the through hole of the tolerance compensating fastener, the second aperture of the second component, and into the opening in the wing nut to assemble the first component and the second component via the tolerance compensating fastener, wherein during the insertion of the threaded fastening element, the tolerance compensating fastener will move in at least one direction from six (6) degrees of freedom to correct misalignment between the first component and the second component.

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