Cage nut assemblies with high float in plane perpendicular to central axis of hole in cage

Abstract

A cage nut assembly includes a nut, a base, and a cage. The nut includes a hollow elongate body and an annular flange. The elongate body has a first end, a second end, a first portion, and a second portion. The annular flange protrudes radially outward from the elongate body. The base has a hole extending therethrough. The cage includes a plate having a hole extending therethrough and sidewalls extending from opposite sides of the plate. The elongate body of the nut extends through the hole in the cage, the second portion of the nut is disposed within the hole in the base, and the second end of the elongate body is at least one of flared radially outward and welded to the base such that the nut is secured to the base and the nut is secured within the cage.

Description

Attorney Docket No. 0275-001790-WO-POACAGE NUT ASSEMBLIES WITH HIGH FLOAT IN PLANE PERPENDICULAR TO CENTRAL AXIS OF HOLE IN CAGECROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present disclosure is a PCT International Application claiming the benefit of U.S. Provisional Application No. 63 / 715,515, filed on November 1 , 2024, and U.S. Provisional Application No. 63 / 789,036, filed on April 15, 2025. The entire disclosure of each application referenced above is incorporated herein by reference.FIELD

[0002] The present disclosure relates to cage nut assemblies with high float in a plane perpendicular to a central axis of a hole in a cage.BACKGROUND

[0003] The background description provided here is for the purpose of generally presenting the context of the disclosure. Work of the presently named inventors, to the extent it is described in this background section, as well as aspects of the description that may not otherwise qualify as prior art at the time of filing, are neither expressly nor impliedly admitted as prior art against the present disclosure.

[0004] Cage nut assemblies include a cage configured to be secured to an object and a nut that is captured within the cage and configured to receive a threaded stud (e.g., a bolt). Typically, the nut is captured within the cage by deforming the cage around the nut or attaching the nut to the cage using adhesive. In an example of the former, referred to as a closed box cage nut, the nut includes a rectangular flange and a cylindrical neck having a threaded hole therein, and the cage includes a rectangular plate and a pair of tabs that extends from opposite longitudinal edges of the plate. The flange of the nut is placed onto a bottom surface formed by the plate of the cage, and then the tabs of the cage are bent around the flange so that the nut is captured between the tabs and the plate.

[0005] The bottom surface of the cage has a hole so that, if a threaded stud is tightened into the threaded hole in the nut and extends through the threaded hole, the bottom surface of the cage does not prevent further tightening of the threaded stud. The hole in the bottom surface is oversized relative to the diameter of the threaded stud to allow forAttorney Docket No. 0275-001790-WO-POA positional tolerances of the threaded stud. The oversized hole may lead to a loss of support of the nut bearing surface (i.e., the surface of the nut supported by the plate of the cage), which in turn may cause the nut flange to bow under high loads.

[0006] To avoid these issues, a four-piece cage nut assembly has been developed. The assembly includes a cage, a nut, a bushing, and a spacer. The cage has a pair of sidewalls that are connected to one another to form a channel with open ends and an open bottom. The bushing has a bowl shape with a flange at the top thereof and a bulge at the bottom thereof. The bulge in the bushing is slid into the channel via one of its open ends and subsequently captured within the channel. The bushing receives the nut, and the spacer fits between a flange on the nut and the flange on the bushing. The cage and the nut are made of metal. The bushing and the spacer are made of plastic.

[0007] Since the cage has an open bottom, the cage allows for full contact between the nut bearing surface and an object to which the cage is secured. However, the assembly requires complex and expensive assembly. In addition, the plastic spacer tends to break and become loose after a threaded stud is tightened into the nut, which requires that an assembler search for the spacer and discard it.

[0008] Therefore, a need exists for a cage nut assembly with an open bottom that is simple and inexpensive to assemble and does not have a component that may break and become loose during or after assembly.

[0009] Rather than capture the nut within the cage by deforming the cage around the nut or attaching the nut to the cage using adhesive, a flange on the nut may be rolled to capture the cage between the flange of the nut and a base of the nut. In such a design, the nut includes a neck that extends from the base to the rolled flange, and there is some clearance between the neck and the hole in the cage to allow the nut to float in a plane perpendicular to the central axis of the hole. However, the amount that the nut is allowed to float is limited, as the flange on the nut may only be rolled so much.

[0010] Therefore, a need exists for an open bottom cage nut assembly with a high amount of allowable float between a nut and a cage within a plane perpendicular to a central axis of a hole in the cage through which the nut extends.SUMMARY

[0011] An example of cage nut assembly according to the present disclosure includes a nut, a base, and a cage. The nut includes a hollow elongate body and an annular flange.Attorney Docket No. 0275-001790-WO-POAThe elongate body has a first end, a second end, a first portion with a first outer diameter, and a second portion with a second outer diameter. The annular flange protrudes radially outward from the elongate body. The base has a first surface, a second surface opposite of the first surface, and a hole extending through the first and second surfaces. The cage includes a plate having a hole extending therethrough and sidewalls extending from opposite sides of the plate. The elongate body of the nut extends through the hole in the cage, the second portion of the nut is disposed within the hole in the base, and the second end of the elongate body is at least one of flared radially outward and welded to the base such that the nut is secured to the base and the nut is secured within the cage.

[0012] In one aspect, the annular flange protrudes radially outward from the elongate body at the first end thereof, and the second outer diameter is less than the first outer diameter to yield a ledge between the first and second portions.

[0013] In one aspect, the second end of the elongate body is flared radially outward, the base is captured between the ledge of the nut and the flared portion of the nut such that the nut is secured to the base, and the plate of the cage is captured between the annular flange of the nut and the first surface of the base such that the nut is secured within the cage.

[0014] In one aspect, the elongate body of the nut has a radial outer surface with a cylindrical shape along the first portion of the elongate body and a polygonal shape along the second portion of the elongate body.

[0015] In one aspect, the hole in the base has the same polygonal shape as the second portion of the elongate body and is sized to yield at least one of a clearance fit and a transition fit between the nut and the base.

[0016] In one aspect, the cage further includes a pair of rectangular tabs projecting in opposite directions from side edges of the sidewalls.

[0017] In one aspect, each tab has a pair of holes extending therethrough for receiving fasteners to secure the cage.

[0018] In one aspect, the cage has an open bottom extending between edges of the sidewalls, and the second end of the nut is swaged such that the second end is flared radially outward.Attorney Docket No. 0275-001790-WO-POA

[0019] In one aspect, the cage is configured to engage a portion of a component surrounding a hole in the component via a snap fit and thereby secure the cage nut assembly within the hole.

[0020] In one aspect, the cage further includes a finger projecting from each sidewall into an opening therein and configured to engage a perimeter of a hole into which the cage nut assembly is installed to inhibit movement of the cage nut assembly in a direction parallel to a plane within which the hole lies.

[0021] In one aspect, the cage further includes a pair of wings projecting from opposite sides of each sidewall and configured to engage a perimeter of a hole into which the cage nut assembly is installed to inhibit movement of the cage nut assembly in a direction perpendicular to a plane within which the hole lies.

[0022] In one aspect, the annular flange protrudes radially outward from the elongate body at a location between the first and second ends thereof, and the nut includes at least one tab projecting from the first end of the elongate body.

[0023] In one aspect, the at least one tab includes a pair of tabs that project axially from the first end of the elongate body and are bent radially outward.

[0024] In one aspect, the second end of the nut is flared radially outward, the base is captured between the annular flange of the nut and the flared portion of the nut such that the nut is secured to the base, and the plate of the cage is captured between the at least one tab of the nut and the first surface of the base such that the nut is secured within the cage.

[0025] Another example of a cage nut assembly according to the present disclosure includes a nut, at least one split pin, and a plate. The nut includes a hollow elongate body and an annular flange. The elongate body has a first end and a second end. The annular flange protrudes radially outward from the elongate body at a location between the first and second ends. The at least one split pin includes a base, a boss projecting axially from the base, and a pair of ears projecting axially from the boss and bent radially outward. The plate has a top surface, a bottom surface, a nut hole extending through the top and bottom surfaces, and at least one pin hole extending through the top and bottom surfaces. The elongate body of the nut extends through the nut hole in the plate and the second end of the elongate body is flared such that the plate is captured between the annular flange of the nut and the flared portion of the nut. The boss of the at least oneAttorney Docket No. 0275-001790-WO-POA split pin extends through the at least one pin hole in the plate and the plate is captured between the ears of the at least one split pin and the base of the at least one split pin.

[0026] In one aspect, the at least one split pin includes a pair of split pins that each include the base, the boss, and the pair of ears, and the at least one pin hole includes a pair of pin holes disposed on opposite sides of the nut hole.

[0027] In one aspect, the at least one pin hole has an inner diameter and the boss of the at least one split pin has an outer diameter that is less than the inner diameter to yield a gap between the at least one split pin and the plate.

[0028] Another example of a cage nut assembly according to the present disclosure includes a nut, a plate, and a cage. The nut includes a hollow elongate body. The elongate body has a first end, a second end, a first portion with a first outer diameter, and a second portion with a second outer diameter. The second outer diameter is less than the first outer diameter to yield a ledge between the first and second portions. The plate includes a strip, a pair of curved ends extending from opposite longitudinal ends of the strip, and a pair of tabs extending from the curved ends and toward one another. The strip has a top surface, a bottom surface, and a hole extending through the top and bottom surfaces. The elongate body of the nut extends through the hole in the plate and the second end of the elongate body projects radially outward such that the plate is captured between the ledge of the nut and the second end of the nut. The cage includes a plate, sidewalls extending from opposite sides of the plate, and a hole extending through the plate. The first portion of the nut extends through the hole in the plate. The cage is captured between the strip of the plate and the tabs of the plate.

[0029] In one aspect, the nut has an outer maximal diameter and the hole in the plate of the cage has an inner diameter that is greater than the outer maximal diameter of the nut to yield a gap between the nut and the cage.

[0030] In one aspect, the nut has a perimeter with a non-circular shape having straight sides and corners joining the sides together, and the second end of the elongate body is swaged at the corners to form rounded tabs.

[0031] Further areas of applicability of the present disclosure will become apparent from the detailed description, the claims and the drawings. The detailed description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the disclosure.Attorney Docket No. 0275-001790-WO-POABRIEF DESCRIPTION OF THE DRAWINGS

[0032] The present disclosure will become more fully understood from the detailed description and the accompanying drawings, wherein:

[0033] FIG. 1 is a top perspective view of a first example of a cage nut assembly according to the principles of the present disclosure, the cage nut assembly including a nut that is shown in its as formed state;

[0034] FIG. 2 is a bottom perspective view of the cage nut assembly of FIG. 1 with the nut in its as formed state;

[0035] FIG. 3 is a bottom planar view of the cage nut assembly of FIG. 1 with the nut in its as formed state;

[0036] FIG. 4 is a sectioned perspective view of the cage nut assembly of FIG. 1 with the nut in its as formed state;

[0037] FIG. 5 is a top perspective view of the cage nut assembly of FIG. 1 after the nut has been deformed to secure the nut to a base and within a cage;

[0038] FIG. 6 is a bottom perspective view of the cage nut assembly of FIG. 1 with the nut in its deformed state;

[0039] FIG.7 is a bottom planar view of the cage nut assembly of FIG. 1 with the nut in its deformed state;

[0040] FIG. 8 is a sectioned perspective view of the cage nut assembly of FIG. 1 with the nut in its deformed state;

[0041] FIG. 9 is a top perspective view of a second example of a cage nut assembly according to the principles of the present disclosure, the cage nut assembly including a nut and a pair of split pins that are shown in their as formed states;

[0042] FIG. 10 is a bottom perspective view of the cage nut assembly of FIG. 9 with the nut and the split pins in their as formed states;

[0043] FIG. 11 is a bottom planar view of the cage nut assembly of FIG. 9 with the nut and the split pins in their as formed states;

[0044] FIG. 12 is a sectioned perspective view of the cage nut assembly of FIG. 9 with the nut and the split pins in their as formed states;Attorney Docket No. 0275-001790-WO-POA

[0045] FIG. 13 is a top perspective view of the cage nut assembly of FIG. 9 after the nut and the split pins have been deformed to secure the nut and the split pins to a plate;

[0046] FIG. 14 is a bottom perspective view of the cage nut assembly of FIG. 9 with the nut and the split pins in their deformed states;

[0047] FIG. 15 is a bottom planar view of the cage nut assembly of FIG. 9 with the nut and the split pins in their deformed states;

[0048] FIG. 16 is a sectioned perspective view of the cage nut assembly of FIG. 9 with the nut and the split pins in their deformed states;

[0049] FIG. 17 is a top perspective view of a third example of a cage nut assembly according to the principles of the present disclosure, the cage nut assembly including a nut that is shown in its as formed state;

[0050] FIG. 18 is a bottom perspective view of the cage nut assembly of FIG. 17 with the nut in its as formed state;

[0051] FIG. 19 is a bottom planar view of the cage nut assembly of FIG. 17 with the nut in its as formed state;

[0052] FIG. 20 is a sectioned perspective view of the cage nut assembly of FIG. 17 with the nut in its as formed state;

[0053] FIG. 21 is a top perspective view of the cage nut assembly of FIG. 17 after the nut has been deformed to secure the nut to a base and within a cage;

[0054] FIG. 22 is a bottom perspective view of the cage nut assembly of FIG. 17 with the nut in its deformed state;

[0055] FIG. 23 is a bottom planar view of the cage nut assembly of FIG. 17 with the nut in its deformed state;

[0056] FIG. 24 is a sectioned perspective view of the cage nut assembly of FIG. 17 with the nut in its deformed state;

[0057] FIG. 25 is a top perspective view of a fourth example of a cage nut assembly according to the principles of the present disclosure, the cage nut assembly including a nut that is shown in its as formed state;

[0058] FIG. 26 is a bottom perspective view of the cage nut assembly of FIG. 25 with the nut in its as formed state;Attorney Docket No. 0275-001790-WO-POA

[0059] FIG. 27 is a bottom planar view of the cage nut assembly of FIG. 25 with the nut in its as formed state;

[0060] FIG. 28 is a sectioned perspective view of the cage nut assembly of FIG. 25 with the nut in its as formed state;

[0061] FIG. 29 is a top perspective view of the cage nut assembly of FIG. 25 after the nut has been deformed to secure the nut to a plate and within a cage;

[0062] FIG. 30 is a bottom perspective view of the cage nut assembly of FIG. 25 with the nut in its deformed state;

[0063] FIG. 31 is a bottom planar view of the cage nut assembly of FIG. 25 with the nut in its deformed state;

[0064] FIG. 32 is a sectioned perspective view of the cage nut assembly of FIG. 25 with the nut in its deformed state;

[0065] FIG. 33 is a top perspective view of a fifth example of a cage nut assembly according to the principles of the present disclosure, the cage nut assembly including a nut that is shown in its as formed state;

[0066] FIG. 34 is a bottom perspective view of the cage nut assembly of FIG. 33 with the nut in its as formed state;

[0067] FIG. 35 is a bottom planar view of the cage nut assembly of FIG. 33 with the nut in its as formed state;

[0068] FIG. 36 is a sectioned perspective view of the cage nut assembly of FIG. 1 with the nut in its as formed state;

[0069] FIG. 37 is a top perspective view of the cage nut assembly of FIG. 33 installed within a hole in a panel; and

[0070] FIG. 38 is a side view of the cage nut assembly of FIG. 33 installed within the hole in the panel.

[0071] In the drawings, reference numbers may be reused to identify similar and / or identical elements.DETAILED DESCRIPTION

[0072] Referring to FIGS. 1 through 8, a cage nut assembly 10 includes a nut 12, a base14, and a cage 16. FIGS. 1 through 5 show components of the cage nut assembly 10 asAttorney Docket No. 0275-001790-WO-POA initially formed and loosely assembled together. FIGS. 5 through 8 show the cage nut assembly 10 after the nut 12 has been deformed to secure the nut 12 to the base 14 and to secure the nut 12 within the cage 16.

[0073] The nut 12 has a hexagonal outer surface 18 defining an outer maximal diameter ODn, and the cage 16 has a hexagonal hole 20 defining an inner maximal diameter IDc. The inner maximal diameter IDc of the hole 20 in the cage 16 is greater than the outer maximal diameter ODn of the nut 12, which yields a gap 22 between the nut 12 and the cage 16 that allows the nut 12 to float relative to the cage 16 within a plane perpendicular to a central axis L1 of the hole 20. The amount of allowable float may be high (e.g., greater than 5 millimeters). Thus, when the cage 16 is secured to an object, the cage nut assembly 10 compensates for misalignment between (i) a longitudinal axis of screw or bolt that is threaded into a cylindrical bore 24 in the nut 12 and (ii) the central axis L1 of the hole 20 in the cage 16.

[0074] The nut 12 includes a hollow elongated body 26 having an upper end 28 and a lower end 30. The hexagonal outer surface 18 is formed on the body 26, and the bore 24 extends through the body 26. The bore 24 is countersunk at the upper and lower ends 28 and 30 of the body 26, yielding conical tapered surfaces 32. The nut 12 further includes an annular flange 34 projecting radially outward from the hexagonal outer surface 18 of the body 26, and a pair of rectangular tabs 36 projecting axially upward from the upper end 28 of the body 26. In various implementations, the nut 12 may have more tabs or fewer tabs (e.g., one tab 36) and the tab(s) 36 may have a shape other than rectangular.

[0075] The base 14 has a rectangular block shape with a top surface 38, a bottom surface 40, and a hexagonal hole 42 extending through the top and bottom surfaces 38 and 40. The hole 42 in the base 14 has an inner maximal diameter IDb that is equal to or slightly greater than the outer maximal diameter ODn of the nut 12. This yields a clearance or transition fit between the nut 12 and the base 14 and prevents the nut 12 from rotating relative to the base 14. With a clearance fit, the hole is larger than the shaft, enabling the two parts to slide and / or rotate relative to one another when assembled. With a transition fit (also referred to as a location fit), the hole is fractionally smaller than the shaft and mild force is required to assemble or disassemble the two parts. In various implementations, the outer surface 18 of the nut 12 and the hole 42 in the base 14 may have a polygonal shape other than hexagonal, such as pentagonal or octagonal.Attorney Docket No. 0275-001790-WO-POA

[0076] The hole 42 is countersunk adjacent to the top surface 38 of the base 14, yielding a conical tapered surface 44. The hole 42 is counterbored adjacent to the bottom surface 40 of the base 14, yielding a conical tapered surface 46 and a flat surface 48. The nut 12 and the base 14 can be made of a carbon steel such as SAE 10B21 , SAE 10B22, or SAE 1035. The nut 12 may be cold formed.

[0077] The cage 16 includes a top plate 52, sidewalls 54 extending downward from opposite sides of the top plate 52, and an open bottom 56 extending between bottom edges of the sidewalls 54. Each sidewall 54 has a pair of feet 58 projecting downward from opposite longitudinal ends of the sidewall 54, and another foot 58 projecting downward from a longitudinal midpoint of the sidewall 54. The cage 16 can be made of a carbon steel, such as SAE 1008 or SAE 1010, which made may be softer or harder than a carbon steel from which the nut 12 and / or the base 14 are made.

[0078] When the nut 12 is initially formed as shown in FIGS. 1 through 4, the tabs 36 extends only axially upward from the upper end 28 of the body 26 (i.e., do not extend radially outward from the body 26), and the entire outer surface 18 is hexagonal. In this state, the tabs 36 and the upper end 28 of the body 26 are inserted through the hole 20 in the cage 16, and the lower end 30 of the body 26 is inserted through the hole 42 in the base 14 until the annular flange 34 engages the top surface 38 of the base 14. Then, the tabs 36 are bent radially outward as best shown in FIGS. 5 and 6, and the lower end 30 of the body 26 is swaged, clinched, or otherwise deformed radially outward as best shown in FIGS. 7 and 8 such that the lower end 30 of the body 26 is flared radially outward.

[0079] To perform the swaging, a swage tool engages the conical tapered surface 32 at the lower end 30 of the nut 12. As a result of the swaging, the outer surface 18 is not hexagonal at the lower end 30 of the nut 12, but rather includes rounded edges 50 that engage the flat surface 48 of the base 14. As a result, the base 14 is captured between the annular flange 34 of the nut 12 and the rounded edges 50 of the nut 12 such that the nut 12 is secured to the base 14. Once the tabs 36 are bent and the nut 12 is secured to the base 14, the top plate 52 of the cage 16 is captured between the tabs 36 and the base 14, which secures the nut 12 within the cage 16. Instead of or in addition to swaging the lower end 30 of the nut 12 to engage the flat surface 48 of the base 14, the lower end 30 may be welded to the flat surface 48 or another surface of the base 14.

[0080] The open bottom 56 of the cage 16 allows for the bottom (or bearing) surface 40 the base 14 to contact an object to which the cage 16 is secured, such as a panel orAttorney Docket No. 0275-001790-WO-POA frame of a vehicle. The cage 16 is secured to the object by inserting the feet 58 of the cage 16 into corresponding holes in the object and welding the feet 58 to the portions of the object surrounding the holes. The top plate 52 of the cage 16 provides a closed surface that enables improved fixturing for securing the cage 16 to the object as the feet 58 of the cage 16 are welded to the object.

[0081] Referring to FIGS. 9 through 16, a cage nut assembly 60 includes a nut 62, a rectangular plate 64, and a pair of split pins 66. FIGS. 9 through 12 show components of the cage nut assembly 60 as initially formed and loosely assembled together. FIGS. 13 through 16 show the cage nut assembly 60 after the nut 62 has been deformed to secure the nut 62 to the plate 64 and after the split pins 66 have been deformed to secure the split pins 66 to the plate 64. In various implementations, the cage nut assembly 60 may include more split pins 66 or fewer split pins 66 (e.g., one split pin 66).

[0082] The nut 62 is similar or identical to the nut 12 of FIGS. 1 through 8 except that the nut 62 does not include the tabs 36. Thus, the reference numbers used herein to refer to the elements of the nut 62 are the same as those used herein to refer to elements of the nut 12.

[0083] The plate 64 has a flat top surface 68 and a stepped bottom surface 70. The plate 64 includes a thick section 72 and a pair of thin sections 74 disposed on opposite sides of the thick section 72. The bottom surface 70 has a pair of fillets 76 at the transitions from the thick section 72 to the thin sections 74.

[0084] The thick section 72 has a hexagonal hole 78 extending through the top and bottom surfaces 68 and 70. The hole 78 receives the nut 62 and has an inner maximal diameter IDn that is equal to or slightly greater than the outer maximal diameter ODn of the nut 62. This yields a clearance or transition fit between the nut 62 and the plate 64 and prevents the nut 62 from rotating relative to the plate 64. The nut 62 is secured to the plate 64 by swaging the nut 62 in the same way that the nut 12 of the FIGS. 1 through 8 is secured to the base 14 by swaging the nut 12. Each thin section 74 has a circular hole 80 extending through the top and bottom surfaces 68 and 70. Each hole 80 receives one of the split pins 66 and has an inner diameter IDp. In various implementations, the outer surface 18 of the nut 62 and the hole 78 in the plate 64 may have a polygonal shape other than hexagonal, such as pentagonal or octagonal.

[0085] Each split pin 66 includes a base 82 having a disk shape, a cylindrical boss 84 projecting axially upward from the center of the base 82, and a pair of ears 86 projectingAttorney Docket No. 0275-001790-WO-POA axially upward from the boss 84. The split pins 66 are secured to the plate 64 by inserting the ears 86 into the holes 80 as shown in FIGS. 9 and 12 and bending the ears 86 radially outward as shown in FIGS. 13 and 16. The split pins 66 are secured to an object by welding bottom surfaces 88 of their bases 82 to the object. Each boss 84 has an outer diameter ODp that is less than the inner diameter IDp of each hole 80 in the plate 64, which yields a gap 90 between each split pin 66 and the plate 64. The gaps 90 allows the nut 12 to float relative to the split pins 66 within a plane perpendicular to central axes L2 of the holes 80. The amount of allowable float may be high (e.g., greater than 5 millimeters). Thus, when the split pins 66 are secured to an object, the cage nut assembly 60 compensates for misalignment between (i) the longitudinal axis of screw or bolt threaded into the cylindrical bore 24 in the nut 12 and (ii) the central axis of the bore 24.

[0086] Referring to FIGS. 17 through 24, a cage nut assembly 100 includes a nut 102, a base 104, and a cage 106. FIGS. 17 through 20 show components of the cage nut assembly 100 as initially formed and loosely assembled together. FIGS. 21 through 24 show the cage nut assembly 100 after the nut 102 has been deformed to secure the nut 102 to the base 104 and to secure the nut 102 within the cage 106.

[0087] The nut 102 has an outer surface 108 defining an outer diameter ODn, and the cage 106 has a circular hole 110 defining an inner diameter IDc. The inner diameter IDc of the hole 1 10 in the cage 106 is greater than the outer diameter ODn of the nut 102, which yields a gap 1 12 between the nut 102 and the cage 106 that allows the nut 102 to float relative to the cage 106 within a plane perpendicular to a central axis L2 of the hole 1 10. The amount of allowable float may be high (e.g., greater than 5 millimeters). Thus, when the cage 106 is secured to an object, the cage nut assembly 100 compensates for misalignment between (i) a longitudinal axis of screw or bolt that is threaded into a cylindrical bore 1 14 in the nut 102 and (ii) the central axis L2 of the hole 110 in the cage 106.

[0088] The nut 102 includes a hollow elongated body 1 16 having an upper end 1 18 and a lower end 120. The body 116 includes a cylindrical portion 122 and a hexagonal portion 124. The cylindrical portion 122 of the body 116 extends from the upper end 1 18 of the body 1 16 to the hexagonal portion 124 of the body 1 16. The hexagonal portion 124 of the body 116 extends from the lower end 120 of the body 1 16 to the cylindrical portion 122 of the body 1 16. The hexagonal portion 124 of the body 1 16 has an outer maximalAttorney Docket No. 0275-001790-WO-POA diameter ODh that is less than the outer diameter ODn of the cylindrical portion 122 of the body 1 16, yielding a step or ledge 126 therebetween.

[0089] The outer surface 108 is cylindrical on the cylindrical portion 122 of the body 1 16, and the outer surface 108 is hexagonal on the hexagonal portion 124 of the body 1 16. The bore 1 14 extends through the body 1 16. The bore 1 14 is countersunk at the upper and lower ends 1 18 and 120 of the body 1 16, yielding conical tapered surfaces 128. The nut 102 further includes an annular flange 130 projecting radially outward from the outer surface 108 of the body 1 16 at the upper end 1 18 thereof. The entire nut 102, including the body 1 16 and the flange 130, may be formed as a single piece or unitary body.

[0090] The base 104 has a rectangular block shape with a top surface 132, a bottom surface 134, and a hexagonal hole 136 extending through the top and bottom surfaces 132 and 134. The hole 136 in the base 104 has an inner diameter I Db that is equal to or slightly greater than the outer maximal diameter ODh of the nut 102. This yields a clearance or transition fit between the nut 102 and the base 104 and prevents the nut 102 from rotating relative to the base 104. The hole 136 is countersunk adjacent to the top and bottom surfaces 132 and 134 of the base 104, yielding conical tapered surfaces 138. The nut 102 and the base 104 can be made of a carbon steel such as SAE 10B21 , SAE 10B22, or SAE 1035. The nut 102 may be cold formed. In various implementations, the outer surface 108 of the portion 124 of the nut 102 and the hole 136 in the base 104 may have a polygonal shape other than hexagonal, such as pentagonal or octagonal.

[0091] The cage 106 includes a top plate 140, sidewalls 142 extending downward from opposite sides of the top plate 140, and a pair of rectangular tabs 146 projecting in opposite directions from the bottom edges of the sidewalls 142. Each tab 146 has a pair of holes 148 extending therethrough for securing the cage 106 to an object using fasteners (e.g., screws). The cage 106 has an open bottom 144 extending between bottom edges of the sidewalls 142. The cage 106 can be made of a carbon steel, such as SAE 1008 or SAE 1010, which made may be softer than a carbon steel from which the nut 102 and the base 104 are made.

[0092] To assemble the cage nut assembly 100, the lower end 120 of the nut 102 is inserted through the hole 1 10 in the cage 106 and into the hole 136 in the base 104 until the ledge 126 of the nut 102 abuts the top surface 132 of the base 104. In turn, the hexagonal portion 124 of the nut 102 engages the hexagonal hole 136 in the base 104.Attorney Docket No. 0275-001790-WO-POAThe lower end 120 of the nut 102 is then swaged or flared to secure the nut 102 to the base 104 and thereby secure the nut 102 within the cage 106.

[0093] To perform the swaging, a swage tool engages the conical tapered surface 128 at the lower end 120 of the nut 102. As a result of the swaging, the outer surface 108 is not hexagonal at the lower end 120 of the nut 102, but rather includes one or more rounded edges 150 that engage the lower conical tapered surface 138 of the base 104 as shown in FIGS. 22 through 24. As a result, the base 104 is captured between the ledge 126 of the nut 102 and the rounded edges 50 of the nut 102 such that the nut 102 is secured to the base 104. In addition, the top plate 140 of the cage 106 is captured between the annular flange 130 of the nut 102 and the top surface 132 of the base 104, which secures the nut 102 within the cage 106. Although FIGS. 22 through 24 depict the swaged or flared lower end 120 of the nut 102 as cylindrical with a single rounded edge 150, the swaged lower end 120 may include multiple rounded edges 150 separated by hexagonal corners like the swaged lower end 30 of the nut 12 in FIGS. 6 through 8. Instead of or in addition to swaging the lower end 120 of the nut 102 to engage the lower conical tapered surface 138 of the base 104, the lower end 120 may be welded to the lower conical tapered surface 138 or another surface of the base 14.

[0094] The open bottom 144 of the cage 106 allows for the bottom (or bearing) surface 134 the base 104 to contact an object to which the cage 106 is secured, such as a panel or frame of a vehicle. The cage 106 is secured to the object by inserting fasteners (e.g., screws) through the holes 148 in the cage 106 and into the object. The top plate 140 of the cage 106 provides a closed surface that enables improved fixturing for securing the cage 106 to the object as the fasteners are inserted through the holes 148 in the cage 106 and into the object. In various implementations, the holes 148 may be omitted, and the cage 106 may be secured the object by welding the tabs 146 to the object.

[0095] Referring to FIGS. 25 through 32, a cage nut assembly 160 includes a nut 162, a plate 164, and a cage 166. FIGS. 25 through 28 show components of the cage nut assembly 160 as initially formed and loosely assembled together. FIGS. 29 through 32 show the cage nut assembly 160 after the nut 162 has been deformed to secure the nut 162 to the plate 164 and to secure the nut 162 within the cage 166.

[0096] The nut 162 has a hexagonal outer surface 168 defining an outer maximal diameter ODn, and the cage 166 has a circular hole 170 defining an inner diameter IDc. The inner diameter IDc of the hole 170 in the cage 166 is greater than the outer maximalAttorney Docket No. 0275-001790-WO-POA diameter ODn of the nut 162, which yields a gap 172 between the nut 162 and the cage 166 that allows the nut 162 to float relative to the cage 166 within a plane perpendicular to a central axis L3 of the hole 170. The amount of allowable float may be high (e.g., greater than 5 millimeters). Thus, when the cage 166 is secured to an object, the cage nut assembly 160 compensates for misalignment between (i) a longitudinal axis of screw or bolt that is threaded into a cylindrical bore 174 in the nut 162 and (ii) the central axis L3 of the hole 170 in the cage 166.

[0097] The nut 162 includes a hollow elongated body 176 having an upper end 178 and a lower end 180. The hexagonal outer surface 168 is formed on the body 176, and the bore 174 extends through the body 176. The bore 174 is countersunk at the upper and lower ends 178 and 180 of the body 176, yielding conical tapered surfaces 182. The hexagonal outer surface 168 of the nut 162 defines the outer maximal diameter ODn at the upper end 178 of the nut 162, and the hexagonal outer surface 168 of the nut 162 defines an outer maximal diameter ODh at the lower end 180 of the nut 162. The outer maximal diameter ODh at the lower end 180 of the nut 162 is less than the outer maximal diameter ODn at the upper end 178 of the nut 162, yielding a step or ledge 184 therebetween. The nut 162 can be made of a carbon steel such as SAE 10B21 , SAE 10B22, or SAE 1035. The nut 162 may be cold formed.

[0098] The plate 164 includes a rectangular strip 186 with a top surface 188, a bottom surface 190, and a hexagonal hole 192 extending through the top and bottom surfaces 188 and 190. The hole 192 in the plate 164 has an inner maximal diameter IDb that is equal to or slightly greater than the outer maximal diameter ODn of the nut 162 at the lower end 180 thereof. This yields a clearance or transition fit between the nut 162 and the plate 164 and prevents the nut 162 from rotating relative to the plate 164. In various implementations, the strip 186 may have a shape other than rectangular. In addition, the outer surface 168 of the nut 162 and the hole 192 in the plate 164 may have a polygonal shape other than hexagonal, such as pentagonal or octagonal.

[0099] The plate 164 further includes half cylindrical sections, curved ends, or rounded ends 194 extending from opposite longitudinal ends of the rectangular strip 186, and rectangular tabs 196 projecting from the rounded ends 194 toward one another. The rectangular tabs 196 are separated from one another by a distance D1 , which is less than a width W of the cage 166. Thus, the cage 166 is captured between the rectangular strip 186 of the plate 164 and the rectangular tabs 196 of the plate 164.Attorney Docket No. 0275-001790-WO-POA

[0100] The cage 166 includes a top plate 200, sidewalls 202 extending downward from opposite sides of the top plate 200, and an open bottom 204 extending between bottom edges of the sidewalls 202. The cage 166 further includes rectangular tabs 206 projecting in opposite directions from the sidewalls 202. Although not shown, each tab 206 may have a pair of holes extending therethrough similar to the holes 148 extending through the tabs 146 as shown in FIGS. 17 through 24. Alternatively, the cage 166 may not include the tabs 206, and each sidewall 202 may have one or more feet projecting downward therefrom, similar to the feet 58 projecting downward from the sidewalls 54 shown in FIGS. 1 through 8, for insertion into holes in an object and welding to the object. The plate 164 and the cage 166 can be made of a carbon steel, such as SAE 1008 or SAE 1010, which made may be softer than a carbon steel from which the nut 162 is made.

[0101] To assemble the cage nut assembly 160, the lower end 180 of the nut 162 is inserted through the hole 170 in the cage 166 and into the hole 192 in the plate 164 until the ledge 184 of the nut 162 abuts the top surface 188 of the plate 164. In turn, the hexagonal outer surface 168 of the nut 162 at its lower end 180 engages the hexagonal hole 192 in the plate 164. The lower end 180 of the nut 162 is then swaged to secure the nut 162 to the plate 164 and thereby secure the nut 162 within the cage 166.

[0102] To perform the swaging, a swage tool engages the lower end 180 of the nut 162 at its hexagonal corners to form rounded tabs 208. As a result, the rounded tabs 208 engage the bottom surface 190 of the plate 164, and the plate 164 is captured between the ledge 184 of the nut 162 and the rounded tabs 208 of the nut 162 such that the nut 162 is secured to the plate 164. In addition, the top plate 200 of the cage 166 is captured between the rectangular strip 186 of the plate 164 and the rectangular tabs 196 of the plate 164, which secures the nut 162 within the cage 166. The lower end 180 of the nut 162 is swaged at its hexagonal corners instead of swaging the lower conical tapered surface 182 because the plate 164 is too thin to withstand the deformation that would occur if the lower conical tapered surface 182 were swaged. Instead of or in addition to swaging the lower end 180 of the nut 162 to engage the bottom surface 190 of the plate 164, the lower end 180 may be welded to the bottom surface 190 or another surface of the plate 164.

[0103] The open bottom 204 of the cage 166 allows for the bottom (or bearing) surface 190 the plate 164 to contact an object to which the cage 166 is secured, such as a panelAttorney Docket No. 0275-001790-WO-POA or frame of a vehicle. The cage 166 may be secured to the object by inserting fasteners (e.g., screws) through the holes (not shown) in the tabs 206 of the cage 166 and into the object. The top plate 200 of the cage 166 provides a closed surface that enables improved fixturing for securing the cage 166 to the object as the fasteners are inserted through the holes in the cage 166 and into the object.

[0104] Referring to FIGS. 33 through 38, a cage nut assembly 210 includes a nut 212, a base 214, and a cage 216. FIGS. 33 through 36 show the cage nut assembly 210 before the nut 212 has been deformed to secure the nut 212 to the base 214 and to secure the nut 212 within the cage 216. FIGS. 37 and 38 show the cage nut assembly 210 installed within a hole 268 in a component 270. In contrast to other examples described herein in where the cage is secured to a component using fasteners, the cage 216 is secured to the component 270 using a snap fit. Also, in contrast to other examples described herein where the tabs or flange of the nut is disposed outside of the cage and the base is disposed within the cage, the annular flange 240 of the nut 212 is disposed within the cage 216 and the base 214 is disposed outside of the cage 216. In this regard, it may be said that the orientation of the nut 212 and the base 214 relative to the cage 216 is flipped upside down relative to other examples described herein.

[0105] The nut 212 has an outer surface 218 defining an outer diameter ODn, and the cage 216 has a circular hole 220 defining an inner diameter IDc. The inner diameter IDc of the hole 220 in the cage 216 is greater than the outer diameter ODn of the nut 212, which yields a gap 222 (FIG. 36) between the nut 212 and the cage 216 that allows the nut 212 to float relative to the cage 216 within a plane perpendicular to a central axis L4 of the hole 220. The amount of allowable float may be high (e.g., greater than 5 millimeters). Thus, when the cage 216 is secured to an object, the cage nut assembly 210 compensates for misalignment between (i) a longitudinal axis of screw or bolt that is threaded into a cylindrical bore 224 in the nut 212 and (ii) the central axis L4 of the hole 220 in the cage 216.

[0106] The nut 212 includes a hollow elongated body 226 having an upper end 228 and a lower end 230. The body 226 includes a cylindrical portion 232 and a hexagonal portion 234, as best shown in FIG. 36. The cylindrical portion 232 of the body 226 extends from the upper end 228 of the body 226 to the hexagonal portion 234 of the body 226. The hexagonal portion 234 of the body 226 extends from the lower end 230 of the body 226 to the cylindrical portion 232 of the body 226. The hexagonal portion 234 of the body 226Attorney Docket No. 0275-001790-WO-POA has an outer maximal diameter ODh (FIG. 35) that is less than the outer diameter ODn of the cylindrical portion 232 of the body 226, yielding a step or ledge 236 therebetween.

[0107] The outer surface 218 is cylindrical on the cylindrical portion 232 of the body 226, and the outer surface 218 is hexagonal on the hexagonal portion 234 of the body 226. The bore 224 extends through the body 226. The bore 224 is countersunk at the upper and lower ends 228 and 230 of the body 226, yielding conical tapered surfaces 238. The nut 212 further includes an annular flange 240 projecting radially outward from the outer surface 218 of the body 226 at the upper end 228 thereof. In the example shown, the nut 212 includes a conical tapered surface 241 (FIG. 36) that forms the underside surface of the annular flange 240.

[0108] The base 214 has a rectangular block shape with a top surface 242, a bottom surface 244, and a hexagonal hole 246 extending through the top and bottom surfaces 242 and 244. The hole 246 in the base 214 has an inner diameter IDb (FIG. 36) that is equal to or slightly greater than the outer maximal diameter ODh of the nut 212. This yields a clearance or transition fit between the nut 212 and the base 214 and prevents the nut 212 from rotating relative to the base 214. The hole 246 is countersunk adjacent to the bottom surface 244 of the base 214, yielding a conical tapered surface 248. The base 214 has two longer side surfaces 243, two shorter side surfaces 245, and four corners 247 at the intersections of the side surfaces 243, 245. The corners 247 of the base 214 may be rounded as shown, and the base 214 may include rounded or tapered transitions 249 from the longer side surfaces 243 to the bottom surface 244. The nut 212 and the base 214 can be made of a carbon steel such as SAE 10B21 , SAE 10B22, or SAE 1035. The nut 212 may be cold formed. In various implementations, the outer surface 218 of the nut 212 and the hole 246 in the base 214 may have a polygonal shape other than hexagonal, such as pentagonal or octagonal.

[0109] The cage 216 includes a bottom plate 250, sidewalls 252 extending upward from opposite longitudinal ends of the bottom plate 250, and a pair of horizontal tabs 254 projecting in opposite directions from the bottom edges of the sidewalls 252. The circular hole 220 extends through the bottom plate 250. In addition, each sidewall 252 forms a rectangular opening 256 with the bottom plate 250, and each sidewall 252 forms a rectangular opening 258 with the horizontal tab 254 projecting therefrom.

[0110] The cage 216 further includes a pair of angled tabs or fingers 260 and two pairs of wings 262. Each finger 260 projects from one of the sidewalls 252 into theAttorney Docket No. 0275-001790-WO-POA corresponding opening 258. Each pair of wings 262 projects from opposite sides of one of the sidewalls 252. The fingers 260 and the wings 262 engage the perimeter of the hole 268 in the component 270 to maintain the cage nut assembly 210 in place during installation of a screw or bolt into the nut 212, and to minimize rattle caused by vibration of the cage 216 relative to the component 270 after the screw or bolt is installed. The cage 216 can be made of a carbon steel, such as SAE 1008 or SAE 1010, which made may be softer than a carbon steel from which the nut 212 and the base 214 are made.

[0111] To assemble the cage nut assembly 210, the lower end 230 of the nut 212 is inserted through the hole 220 in the cage 216 and into the hole 246 in the base 214 until the ledge 236 of the nut 212 abuts the top surface 242 of the base 214. In turn, the hexagonal portion 234 of the nut 212 engages the hexagonal hole 246 in the base 214. The lower end 230 of the nut 212 is then swaged or flared to secure the nut 212 to the base 214 and thereby secure the nut 212 within the cage 216.

[0112] To perform the swaging, a swage tool engages the conical tapered surface 238 at the lower end 230 of the nut 212. As a result of the swaging, the outer surface 218 may not be hexagonal at the lower end 230 of the nut 212 as shown, but rather may include one or more rounded edges that engage the lower conical tapered surface 248 of the base 214. For example, the lower end 230 of the nut 212 may include a plurality of rounded edges extending between points of formerly hexagonal perimeter such as rounded edges 50 shown in FIGS. 6 and 7, or the lower end 230 of the nut 212 may include a single rounded edge such as rounded edge 150 shown in FIGS. 22 and 23. After the swaging, the base 214 is captured between the ledge 236 of the nut 212 and the one or more rounded edges of the nut 212 such that the nut 212 is secured to the base 214. In addition, the bottom plate 250 of the cage 216 is captured between the annular flange 240 of the nut 212 and the top surface 242 of the base 214, which secures the nut 212 within the cage 216. Instead of or in addition to swaging the lower end 230 of the nut 212 to engage the lower conical tapered surface 248 of the base 214, the lower end 230 may be welded to the lower conical tapered surface 248 or another surface of the base 214.

[0113] Referring now to FIGS. 37 and 38, installation of the cage nut assembly 210 onto the component 270 will now be described. In the example shown, the component includes a top portion 272, side portions 274, a bottom portion 276, and fillets 278 extending between the side portions 274 and the bottom portion 276. The hole 268Attorney Docket No. 0275-001790-WO-POA extends through the top portion 272 of the component 270, but the hole 268 does not extend through the bottom portion 276 of the component 270.

[0114] To install the cage nut assembly 210 onto the component 270, the cage nut assembly 210 is inserted into the hole 268 of the component 270 until the base 214 of the cage nut assembly 210 contacts the bottom portion 276 of the component 270 as shown. This may be accomplished by, for example, grabbing the annular flange 240 of the nut 212 by hand, aligning the base 214 with the hole 268, and then inserting the cage nut assembly 210 into the hole 268. Thus, as with other examples described herein, the bottom surface 244 of the base 214 is allowed to contact the component 270 to which the cage 216 is secured. As the cage nut assembly 210 is inserted into the hole 268, angled side edges 263 of the wings 262 engage the perimeter of the hole 268 and thereby cause the sidewalls 252 of the cage 216 to deflect toward one another.

[0115] The sidewalls 252 of the cage 216 continue to deflect toward one another until the wings 262 of the cage 216 are inserted completely through the hole 268 in the component 270. At that point, the sidewalls of the cage 216 return to their relaxed state such that the top portion 272 of the component 270 is captured between the horizontal tabs 254 and the wings 262 as shown, which inhibits movement of the cage nut assembly 210 relative to the component 270 in a vertical direction V (i.e., a direction perpendicular to a plane within which the hole 268 lies). In turn, the fingers 260 engage the perimeter of the hole 268 in the component 270 and apply a biasing force thereto that inhibits movement of the cage nut assembly 210 relative to the component 270 in a horizontal direction H (i.e., a direction parallel to the plane within which the hole 268 lies).

[0116] Engagement between the longitudinal sides 243 of the base 214 and the side portions 274 of the component 270 may limit or inhibit rotation of the nut 212 and the base 214 as a screw or bolt is threaded into the bore 224 in the nut 212. The tapered transitions 249 on the base 214 provide a clearance for the fillets 278 on the component 270. The entire base 214 except for the tapered transitions 249 may be formed by stamping, and then the tapered transitions 249 may be formed by edge rolling.

[0117] The foregoing description is merely illustrative in nature and is in no way intended to limit the disclosure, its application, or uses. The broad teachings of the disclosure can be implemented in a variety of forms. Therefore, while this disclosure includes particular examples, the true scope of the disclosure should not be so limited since other modifications will become apparent upon a study of the drawings, the specification, andAttorney Docket No. 0275-001790-WO-POA the following claims. It should be understood that one or more steps within a method may be executed in different order (or concurrently) without altering the principles of the present disclosure. Further, although each of the embodiments is described above as having certain features, any one or more of those features described with respect to any embodiment of the disclosure can be implemented in and / or combined with features of any of the other embodiments, even if that combination is not explicitly described. In other words, the described embodiments are not mutually exclusive, and permutations of one or more embodiments with one another remain within the scope of this disclosure.

[0118] When an element or layer is referred to as being "on," "engaged to," "connected to," or "coupled to" another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being "directly on," "directly engaged to," "directly connected to," or "directly coupled to" another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., "between" versus "directly between," "adjacent" versus "directly adjacent," etc.).

[0119] Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and / or sections, these elements, components, regions, layers and / or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as "first," "second," and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.

[0120] Spatially relative terms, such as "inner," "outer," "beneath," "below," "lower," "above," "upper," and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as "below" or "beneath" other elements or features would then be oriented "above" the other elements or features. Thus, the example term "below" can encompass both an orientation of aboveAttorney Docket No. 0275-001790-WO-POA and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

[0121] As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items. As used herein, the phrase at least one of A, B, and C should be construed to mean a logical (A OR B OR C), using a non-exclusive logicalOR, and should not be construed to mean “at least one of A, at least one of B, and at least one of C.”

Claims

Attorney Docket No. 0275-001790-WO-POACLAIMSWhat is claimed is:

1. A cage nut assembly comprising: a nut including a hollow elongate body and an annular flange, the elongate body having a first end and a second end, the annular flange protruding radially outward from the elongate body, the elongate body having a first portion with a first outer diameter and a second portion with a second outer diameter; a base having a first surface, a second surface opposite of the first surface, and a hole extending through the first and second surfaces; and a cage including a plate having a hole extending therethrough and sidewalls extending from opposite sides of the plate, wherein the elongate body of the nut extends through the hole in the cage, the second portion of the nut is disposed within the hole in the base, and the second end of the elongate body is at least one of flared radially outward and welded to the base such that the nut is secured to the base and the nut is secured within the cage.

2. The cage nut assembly of claim 1 wherein the annular flange protrudes radially outward from the elongate body at the first end thereof, and the second outer diameter is less than the first outer diameter to yield a ledge between the first and second portions.

3. The cage nut assembly of claim 2 wherein the second end of the elongate body is flared radially outward, the base is captured between the ledge of the nut and the flared portion of the nut such that the nut is secured to the base, and the plate of the cage is captured between the annular flange of the nut and the first surface of the base such that the nut is secured within the cage.

4. The cage nut assembly of any one of claims 1 to 3 wherein the elongate body of the nut has a radial outer surface with a cylindrical shape along the first portion of the elongate body and a polygonal shape along the second portion of the elongate body.

5. The cage nut assembly of claim 4 wherein the hole in the base has the same polygonal shape as the second portion of the elongate body and is sized to yield at least one of a clearance fit and a transition fit between the nut and the base.Attorney Docket No. 0275-001790-WO-POA6. The cage nut assembly of any one of claims 1 to 5 wherein the cage further includes a pair of rectangular tabs projecting in opposite directions from side edges of the sidewalls.

7. The cage nut assembly of claim 6 wherein each tab has a pair of holes extending therethrough for receiving fasteners to secure the cage.

8. The cage nut assembly of any one of claims 1 to 7 wherein the cage has an open bottom extending between edges of the sidewalls, and the second end of the nut is swaged such that the second end is flared radially outward.

9. The cage nut assembly of any one of claims 1 to 5 wherein the cage is configured to engage a portion of a component surrounding a hole in the component via a snap fit and thereby secure the cage nut assembly within the hole.

10. The cage nut assembly of claims 1 or 9 wherein the cage further includes a finger projecting from each sidewall into an opening therein and configured to engage a perimeter of a hole into which the cage nut assembly is installed to inhibit movement of the cage nut assembly in a direction parallel to a plane within which the hole lies.1 1 . The cage nut assembly of claims 1 , 9, or 10 wherein the cage further includes a pair of wings projecting from opposite sides of each sidewall and configured to engage a perimeter of a hole into which the cage nut assembly is installed to inhibit movement of the cage nut assembly in a direction perpendicular to a plane within which the hole lies.

12. The cage nut assembly of claim 1 wherein the annular flange protrudes radially outward from the elongate body at a location between the first and second ends thereof, and the nut includes at least one tab projecting from the first end of the elongate body.

13. The cage nut assembly of claim 12 wherein the at least one tab includes a pair of tabs that project axially from the first end of the elongate body and are bent radially outward.

14. The cage nut assembly of claims 12 or 13 wherein the second end of the nut is flared radially outward, the base is captured between the annular flange of the nut andAttorney Docket No. 0275-001790-WO-POA the flared portion of the nut such that the nut is secured to the base, and the plate of the cage is captured between the at least one tab of the nut and the first surface of the base such that the nut is secured within the cage.

15. A cage nut assembly comprising: a nut including a hollow elongate body and an annular flange, the elongate body having a first end and a second end, the annular flange protruding radially outward from the elongate body at a location between the first and second ends; at least one split pin including a base, a boss projecting axially from the base, and a pair of ears projecting axially from the boss and bent radially outward; and a plate having a top surface, a bottom surface, a nut hole extending through the top and bottom surfaces, and at least one pin hole extending through the top and bottom surfaces, wherein the elongate body of the nut extends through the nut hole in the plate and the second end of the elongate body is flared such that the plate is captured between the annular flange of the nut and the flared portion of the nut, and wherein the boss of the at least one split pin extends through the at least one pin hole in the plate and the plate is captured between the ears of the at least one split pin and the base of the at least one split pin.

16. The cage nut assembly of claim 15 wherein the at least one split pin includes a pair of split pins that each include the base, the boss, and the pair of ears, and the at least one pin hole includes a pair of pin holes disposed on opposite sides of the nut hole.

17. The cage nut assembly of claims 15 or 16 wherein the at least one pin hole has an inner diameter and the boss of the at least one split pin has an outer diameter that is less than the inner diameter to yield a gap between the at least one split pin and the plate.

18. A cage nut assembly comprising: a nut including a hollow elongate body, the elongate body having a first end, a second end, a first portion with a first outer diameter, and a second portion with a second outer diameter, wherein the second outer diameter is less than the first outer diameter to yield a ledge between the first and second portions;Attorney Docket No. 0275-001790-WO-POA a plate including a strip, a pair of curved ends extending from opposite longitudinal ends of the strip, and a pair of tabs extending from the curved ends and toward one another, the strip having a top surface, a bottom surface, and a hole extending through the top and bottom surfaces, wherein the elongate body of the nut extends through the hole in the plate and the second end of the elongate body projects radially outward such that the plate is captured between the ledge of the nut and the second end of the nut; and a cage includes a plate, sidewalls extending from opposite sides of the plate, and a hole extending through the plate, the first portion of the nut extending through the hole in the plate, wherein the cage is captured between the strip of the plate and the tabs of the plate.

19. The cage nut assembly of claim 18 wherein the nut has an outer maximal diameter and the hole in the plate of the cage has an inner diameter that is greater than the outer maximal diameter of the nut to yield a gap between the nut and the cage.

20. The cage nut assembly of claims 18 or 19 wherein the nut has a perimeter with a non-circular shape having straight sides and corners joining the sides together, and the second end of the elongate body is swaged at the corners to form rounded tabs.

Images