Insulating Cage Nut One-Piece Isolator Design
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Solution Overview
Problem
Existing electrically insulating cage nuts have a cumbersome and unreliable manufacturing process and are not robust in all installation positions, particularly during electrostatic coating processes.
Innovation Solution
A one-piece isolator device with a hollow cylindrical body and flatly extending insulator plates is used, firmly attached to the cylindrical extension, allowing for easy assembly and enhanced stability by preventing direct contact between the nut body and cage, using a press fit, adhesive bonding, or caulking, and ensuring radial movement of the cage edge relative to the axis of rotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a two-part insulator element with insulating washer is used, then electrical insulation is achieved, but the manufacturing process becomes cumbersome and tedious
Solution Approach 1:
The patent combines multiple insulator components (insulator element and insulating washer) into a single one-piece insulator device with integrated hollow cylindrical body and insulator plates, eliminating the need for separate assembly steps and reducing manufacturing complexity while maintaining electrical insulation functionality
2Reliability
If a two-part insulator element is used, then electrical insulation is provided, but the construction becomes less reliable and robust in installation positions
Solution Approach 1:
The integrated one-piece construction of the insulator device with its hollow cylindrical body and insulator plates provides a more stable and reliable structure that maintains electrical insulation and mechanical stability in all installation positions including overhead and side-mounted configurations during electrostatic coating processes
Solution Approach 2:
The insulator device is segmented into functional zones with the hollow cylindrical body providing structural support and the insulator plates providing electrical isolation surfaces, creating a robust design that performs reliably in various installation orientations
3Ease of manufacture
If the opening diameter is larger than the cylindrical boss diameter, then assembly is facilitated, but electrical insulation reliability may be compromised
Solution Approach 1:
The one-piece insulator device acts as an intermediary element between the cage opening and the cylindrical boss, with its hollow cylindrical body fitting through the opening and insulator plates providing electrical isolation, thereby maintaining both assembly ease and insulation reliability despite the diameter mismatch
Data Source
Figure 1~6
AI summary
An electrically insulating cage nut (10) having a nut body (12) which is held in a cage (14), in which the nut body (12) has a cylindrical attachment (16) and a broadened holding element (18), and the cylindrical attachment (16) has an internal thread (20) and extends through an opening (22) in the cage (14) to the outside, wherein the internal diameter of the opening (22) is substantially larger than the external diameter of the cylindrical attachment (16), but is smaller than the external size of the holding element (18), and an insulator apparatus (24) is arranged between the cage (14) and cylindrical attachment (16), wherein the insulator apparatus (24) is formed integrally, and in consequence the cage nut (10) consists of only three components (12, 14, 24).