Self-Aligning Washer-Nut Assembly for Offset Angle Fasteners
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Solution Overview
Problem
Existing nut and washer assemblies in manufacturing require manual alignment and handling of multiple components, which is time-consuming and costly, especially when dealing with offset angle fasteners, and existing solutions like concave washers, convex nuts, or tapered fillers complicate the process and require additional tooling or steps.
Innovation Solution
A self-retaining washer and nut assembly with a retaining flange and positioning cavity, manufactured using additive manufacturing, allowing for offset angle positioning with spherical engagement surfaces and a blocking surface to maintain contact at maximum angles, ensuring consistent part dimensions and quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual alignment of separate nuts and washers is used, then alignment of offset angle fasteners can be achieved, but assembly time increases and risk of mishandling or loss increases
Solution Approach 1:
The patent combines the washer and nut into a single integrated assembly where the nut is retained within the washer structure. The washer includes a recess that receives and retains the nut, eliminating the need for separate handling and manual alignment of two distinct components. This merging resolves the contradiction by maintaining alignment accuracy while significantly reducing assembly time and handling complexity.
2Reliability
If concave washer and convex nut combination is used, then offset angle alignment is achieved, but device complexity and number of components increases
Solution Approach 1:
The patent integrates the nut within the washer structure, creating a single-component assembly that provides offset angle accommodation. The washer includes a recess with engagement surfaces that work with corresponding surfaces on the nut to accommodate offset angles, eliminating the need for separate concave washer and convex nut components while maintaining the same functional capability.
Solution Approach 2:
The integrated washer-nut assembly serves multiple functions within a single structure: the washer provides the base mounting surface, the recess retains the nut, and the engagement surfaces between the recess and nut accommodate offset angle fasteners. This multi-functionality reduces device complexity while maintaining offset angle accommodation capability.
3Reliability
If tapered filler is added, then offset angle alignment is achieved, but device complexity and number of manufacturing steps increases
Solution Approach 1:
The patent combines the filler function into the integrated washer-nut structure. The recess in the washer and the corresponding engagement surfaces on the nut work together to provide the offset angle accommodation that would otherwise require a separate tapered filler. This merging eliminates the need for additional manufacturing steps such as drilling holes through separate fillers.
4Manufacturing precision
If spot-facing is performed, then surface perpendicularity is improved, but additional tooling and manufacturing time is required
Solution Approach 1:
The patent incorporates the alignment and perpendicularity functions into the pre-manufactured integrated washer-nut assembly. The engagement surfaces between the recess and nut are designed with precise geometries that automatically provide the necessary alignment and perpendicularity when assembled, eliminating the need for post-assembly spot-facing operations and additional tooling.
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 solution enables efficient and cost-effective assembly of nut and washer combinations that can handle offset angle fasteners with full circumferential contact, reducing handling complexities and tooling requirements while ensuring reliable retention and alignment.
Implementation Method 1
manufactured using additive manufacturing
Implementation Method 2
The binder is cured to solidify a metal matrix in the structure of the washer and nut
Implementation Method 3
The metal matrix is then sintered
Implementation Method 4
The binder is removed by solvent wash or heat vaporization
Implementation Method 5
The binder is removed by solvent wash or heat vaporization
Implementation Method 6
The ceramic intermediary is vaporized in an oven cure leaving the consolidated metal washer and retained nut
Data Source
Figure 1A
Figure 1B
Figure 2
AI summary
A washer and retained nut assembly (8) has a washer (12) with a retaining flange (38) and a positioning cavity (44) and a nut (10) received in the washer. The nut has a shoulder (36) received in the positioning cavity with a top surface (42) of the shoulder engaging a lower surface (40) of the retaining flange in a loose condition of the washer and nut. The nut further has an engagement surface (24) contacting a receiving surface (26) in the washer in an engaged position of the washer and nut. The nut further has a peripheral surface (28) engaging a blocking surface (70) in the washer with the nut and washer in a maximum offset angle orientation between the washer and nut in the engaged position.