Cage Nut Assembly With Annular Flange Capture and Open-Bottom Support

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Solution Overview

Problem

Existing cage nut assemblies face issues with assembly complexity and component breakage or loosening, particularly due to the use of open-bottom cages and plastic spacers, which complicate and increase costs.

Innovation Solution

A cage nut assembly design featuring a nut with an annular flange and a cage with an open bottom, where the nut is secured within the cage by deforming the flange without adhesives, allowing for simple assembly and using carbon steel components to prevent breakage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If a four-piece cage nut assembly with plastic spacer is used, then the open bottom cage allows full contact between nut bearing surface and object, but the assembly becomes complex and expensive

Engineering Contradiction:

Improvecontact between nut bearing surface and objectVSAvoidassembly complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The patent combines the cage and nut into a two-piece assembly where the nut is directly captured within the cage by deforming cage tabs around the nut flange. This eliminates the need for separate plastic spacers and bushings, reducing assembly complexity while maintaining the open bottom design that allows full bearing surface contact.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent removes the plastic spacer and bushing components from the assembly, extracting only the essential cage and nut elements. This simplification eliminates the complexity of assembling multiple pieces while preserving the functional benefit of open bottom contact.

Inventive Principle:

Principle #2Taking out (Extraction)

2Ease of operation

If a four-piece cage nut assembly with plastic spacer is used, then the open bottom cage allows full contact between nut bearing surface and object, but the plastic spacer tends to break and become loose

Engineering Contradiction:

Improvecontact between nut bearing surface and objectVSAvoidcomponent stability

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent eliminates the use of plastic spacers that are prone to breaking and becoming loose. By using a metal cage with deformable tabs that permanently capture the metal nut, the design removes the disposable plastic component that causes reliability issues, while maintaining the open bottom functional design.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent uses metal materials for both the cage and nut components, replacing the plastic spacer with a metal-based capture mechanism. This composite approach using metal tabs and metal nut provides superior reliability compared to plastic components that break and loosen.

Inventive Principle:

Principle #40Composite materials

3Device complexity

If the nut is captured by deforming the cage around the nut, then the assembly is simpler, but the oversized hole in the bottom surface leads to loss of support and nut flange bowing

Engineering Contradiction:

Improveassembly simplicityVSAvoidnut bearing surface support

Core Design Contradiction:

Device complexityVSStrength

Solution Approach 1:

The patent applies local quality by having the cage tabs deform locally around the nut flange to create a secure capture mechanism. The tabs are positioned to provide localized support at critical points around the nut, maintaining bearing surface support while keeping the overall design simple and avoiding the need for oversized holes.

Inventive Principle:

Principle #3Local quality

4Reliability

If adhesive is used to attach the nut to the cage, then the nut is secured, but the assembly process becomes more complex and time-consuming

Engineering Contradiction:

Improvenut to cage attachmentVSAvoidassembly speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent replaces the chemical bonding method (adhesive) with a mechanical capture system. The cage tabs are deformed mechanically around the nut flange to create a secure attachment. This mechanical substitution eliminates the need for adhesive application and curing time, significantly improving assembly productivity while maintaining reliable attachment.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The design provides a cost-effective, robust assembly that compensates for misalignment and maintains secure attachment, ensuring the nut remains intact during and after assembly.

Implementation Method 1

deforming the flange and thereby capturing the plate of the cage between the flange of the nut and a base of the nut

Methodology Applied

Scientific EffectDeformation: Deformation

Data Source

PatentUS20260029015A1Cage nut assembly including nut annular flange capturing cage and method of manufacturing the same

Publication Date: 2026.01.29 NEWFREY LLC

AI summary

A cage nut assembly is disclosed that includes a cage and a nut. The cage includes a plate having a hole, sidewalls extending from opposite sides of the plate, and an open bottom extending between bottom edges of the sidewalls. The nut includes a base, a neck, and a flange. The neck extends through the hole in the cage. The flange and the base of the nut capture the plate of the cage therebetween to secure the nut within the cage. A method of making such a cage nut assembly is also disclosed.