Spherical Nut Sleeve for Flush Crane Mat Fastening
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Solution Overview
Problem
Existing fastening systems for crane mats, such as those used in the construction industry, require countersinking and the use of longer bolts to accommodate variations in timber dimensions, leading to increased costs, labor, and safety risks due to the need for torching and potential gaps between mats.
Innovation Solution
A spherical nut sleeve with a pass-through and internally threaded bore allows for a single bolt length to be used across varying widths, eliminating the need for countersinking and enabling tighter tolerances, faster assembly, and safer manufacturing processes by providing a self-centering and compact fastening system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If countersinking is used to recess the nut and washer, then the mats can be kept tighter together and the nut-washer does not stick out, but additional capital cost, labor cost, and manufacturing complexity are incurred
Solution Approach 1:
Instead of modifying the mat structure by countersinking to accommodate a standard nut, the invention inverts the approach by making the nut itself spherical and self-recessing. The spherical nut's geometry allows it to sit flush against the mat surface without requiring the mat to be pre-modified, thereby eliminating the countersinking operation while achieving the same aesthetic and functional result.
Solution Approach 2:
The spherical nut is designed to be self-contained and self-installing. Its spherical geometry with integrated washer surface allows it to automatically position itself flush against the mat surface upon installation, eliminating the need for separate countersinking operations or additional components. The nut serves its own recessing function through its inherent shape.
2Reliability
If countersinking is used to allow nut-washer to reach short bolts, then proper fastening is achieved, but additional labor and equipment costs are incurred
Solution Approach 1:
Rather than modifying the mat structure to accommodate standard nuts and short bolts, the invention inverts the solution by designing a spherical nut with an extended stud that protrudes through the mat surface. This allows the threading portion to engage short bolts effectively without requiring the mat to be countersunk, maintaining fastening reliability while simplifying manufacturing.
Solution Approach 2:
The spherical nut is segmented into distinct functional zones: a spherical head portion that provides the flush surface, an extended stud portion that protrudes to engage short bolts, and an integrated washer surface. This segmentation allows each portion to perform its specific function independently, enabling the nut to reach short bolts without modifying the mat structure.
3Adaptability or versatility
If varying bolt lengths are used to accommodate mat width variations, then proper fastening is achieved, but inventory costs and manufacturing complexity increase
Solution Approach 1:
The spherical nut with extended stud is designed as a universal fastening component that can accommodate varying mat widths and bolt lengths through its geometric design. The extended stud portion can engage bolts of different lengths, and the spherical head adapts to different mat thicknesses, eliminating the need for multiple specialized bolt and nut combinations.
Solution Approach 2:
The spherical nut design provides dynamic adaptability through its geometry. The spherical head can accommodate variations in mat thickness, and the extended stud can engage with bolts of varying lengths, allowing a single nut design to dynamically adapt to different fastening scenarios without requiring inventory of multiple specialized components.
4Adaptability or versatility
If longer bolts are used to span varying mat widths, then fastening is achieved, but cost and potential safety risks from torching increase
Solution Approach 1:
The spherical nut with extended stud serves as a universal fastening solution that works with standard-length bolts across varying mat widths. The extended stud portion compensates for width variations, eliminating the need for excessively long bolts that would require torching for installation, thereby reducing safety risks associated with hot work.
Solution Approach 2:
The extended stud on the spherical nut acts as an intermediary element between the standard bolt and the varying mat width. Instead of requiring the bolt itself to be excessively long (which would need torching), the extended stud mediates the connection, allowing standard-length bolts to effectively span varying widths without hot work.
Data Source
AI summary
A nut to be used as part of a fastener to be used in multiple ways in various industries or methods has a drive mechanism and stud extending from the drive mechanism with a threaded bore. In addition the nut can be specifically used as a method and as part of special fastener that can be used to join cut, hard-wood members, other naturally occurring manufactured mat members or synthetically man made members, referred to as “timber(s)” or “laminated”, in forming a mat used for heavy construction equipment to run on over ground which is not stable. These mats are commonly referred to as “Crane Mats” or “Laminated Mats” in the construction, mining, pipeline, and oil and gas industries among others.