Self-Aligning Washer-Nut Assembly for Offset Angle Fastening
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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 either require additional tooling or complex handling procedures.
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, eliminating the need for multiple components and complex alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual alignment of separate nuts and washers is used, then assembly flexibility is maintained, but assembly time increases and handling errors occur
Solution Approach 1:
The patent combines the nut and washer into a single integrated fastening assembly where the washer serves as a mounting platform for the nut. The washer includes a recess that receives the nut, and both components are pre-aligned during manufacturing. This merging eliminates the need for manual alignment of separate components during assembly, directly resolving the contradiction by reducing assembly time while maintaining the functional separation of the nut and washer through their integrated design.
2Manufacturing precision
If multiple fitted individual components are used for offset angle accommodation, then alignment accuracy improves, but handling complexity and cost increase
Solution Approach 1:
The patent incorporates alignment features directly into the washer and nut assembly during manufacturing. The washer includes a recess with specific geometry that pre-positions the nut at the correct angle relative to the fastener hole. This preliminary alignment action eliminates the need for manual alignment operations and reduces handling complexity, as the assembly arrives pre-configured for the required offset angle accommodation.
Solution Approach 2:
The integrated fastening assembly is designed with distinct functional segments: the washer body provides the mounting surface, the recess provides nut retention, and the geometry of these features provides alignment. This segmentation of functions within a single integrated component allows precise alignment control while simplifying handling compared to multiple separate alignment components.
3Manufacturing precision
If spot-facing is performed to accommodate non-perpendicular surfaces, then fastener installation accuracy improves, but additional tooling and time are required
Solution Approach 1:
The washer is designed with a bottom surface that self-adapts to non-perpendicular mounting surfaces. The geometry of the washer body and its recess allows it to maintain proper alignment of the fastener hole even when the mounting surface is not perfectly perpendicular. This self-aligning capability eliminates the need for spot-facing operations, saving time and eliminating the need for additional tooling while maintaining fastener installation accuracy.
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
Enables efficient and cost-effective assembly of fasteners at various angles while ensuring consistent part quality and minimizing handling errors, as the washer and nut remain together from manufacture through assembly, optimizing retention interface geometry.
Implementation Method 1
microlayers are printed using a metal powder and binder formulation for a washer and nut structure
Implementation Method 2
The ceramic intermediary is vaporized in an oven cure leaving the consolidated metal washer and retained nut with an intervening positioning cavity
Implementation Method 3
The binder is removed by solvent wash or heat vaporization
Implementation Method 4
The metal matrix is then sintered. The binder is removed by solvent wash or heat vaporization. The remaining metal matrix is then consolidated.
Data Source
AI summary
A washer and retained nut assembly has a washer with a retaining flange and a positioning cavity and a nut received in the washer. The nut has a shoulder received in the positioning cavity with a top surface of the shoulder engaging a lower surface of the retaining flange in a loose condition of the washer and nut. The nut further has an engagement surface contacting a receiving surface in the washer in an engaged position of the washer and nut. The nut further has a peripheral surface engaging a blocking surface in the washer with the nut and washer in a maximum offset angle orientation between the washer and nut in the engaged position.