Integrated Nutplate and Clip for Floating Fastener Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing floating fastener designs are costly and unreliable, with high per-hole costs due to complex machining and assembly processes, and often result in installation damage or performance failures, especially in blind access applications where alignment and torque resistance are challenging.
Innovation Solution
An integrated nutplate is manufactured into the interior structural member with a retention clip that captures the nut, allowing it to float and provide torque and axial resistance, reducing the need for separate nutplates and assembly tools, and utilizing high-speed milling for efficient production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If discrete nutplates are machined and crimped to capture the nut, then the floating fastener can accommodate misalignment, but the manufacturing cost and complexity increase significantly
Solution Approach 1:
The patent merges the nutplate and structural member into a single integrated component, eliminating the need for separate nutplate machining and crimping operations. The nutplate features are directly formed as part of the structural member during primary manufacturing, capturing the nut while allowing floating movement to accommodate misalignment without requiring complex post-processing operations.
Solution Approach 2:
The nutplate features are pre-formed into the structural member during the primary manufacturing process before assembly. This preliminary action creates the floating fastener capture geometry in advance, eliminating the need for complex field assembly operations and reducing both manufacturing complexity and assembly time.
2Reliability
If traditional riveted or bonded methods are used to secure the nutplate, then axial and torque resistance are provided, but the assembly cost and potential installation damage increase
Solution Approach 1:
The patent combines the nutplate securing function directly into the structural member through integrated features such as recesses, undercuts, or interlocking geometries. This eliminates the need for separate riveting or bonding operations, providing reliable axial and torque resistance while simplifying the assembly process to a single integrated manufacturing step.
Solution Approach 2:
The patent replaces mechanical fastening systems (rivets, adhesives) with integrated structural features that provide equivalent or superior mechanical resistance. The integrated design uses the structural member's own geometry to provide axial and torque resistance, eliminating the need for additional mechanical fasteners or chemical adhesives.
3Reliability
If multiple separate components are used for the floating fastener, then reliability can be maintained, but the per-hole cost accumulates quickly
Solution Approach 1:
The patent consolidates multiple separate components (structural member, nutplate, retention features) into a single integrated component. This merging reduces the total number of parts from three or more to one, lowering material costs, inventory requirements, and assembly complexity while maintaining all necessary functional features for reliable fastener installation.
Solution Approach 2:
The integrated structural member performs multiple functions simultaneously: it provides the primary structural function, incorporates the nutplate features for fastener capture, and includes retention features for axial and torque resistance. This multi-functionality eliminates the need for separate specialized components, reducing the total component count while maintaining reliability.
4Reliability
If precision machining is used to align the nutplate and nut, then assembly reliability improves, but manufacturing cost increases
Solution Approach 1:
The patent merges the alignment function into the integrated manufacturing process. Since the nutplate features are formed as part of the structural member in a single manufacturing operation, alignment precision is inherent to the integrated geometry rather than requiring separate precision machining and assembly operations. The floating fastener capture features are automatically aligned through the integrated design.
Data Source
AI summary
An inexpensive and reliable floating fastener is provided by manufacturing an integrated nutplate into the backside of the interior structural member. A retention clip engages the nutplate to capture the nut while allowing the nut to float. The integrated nutplate roughly aligns the floating nut to the axial through-hole in the structural member and provides the torque resistance required to drive the screw into the nut. The retention clip holds the nut in place and provides the axial resistance required for the lead chamfer of the screw to engage the nut and resist the axial loading on the screw during installation. The nutplate is designed to facilitate cost-effective manufacturing. The per hole cost of the integrated floating-fastener is approximately 30% of the cost of the industry standard riveted floating fastener.