T-nut Collation via Mechanical Interlock and Progressive Die
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Solution Overview
Problem
Current methods for collating T-nuts using tape are prone to detachment due to temperature and humidity changes, lack structural rigidity, and fail to withstand impact, leading to instability and inefficiencies in handling and installation.
Innovation Solution
A method involving a progressive die process to form and tap T-nuts on a continuous steel or stainless steel strip, allowing for secure collation without secondary processes, enabling automated installation and improved handling through a stable coil form.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If T-nuts are adhered to tape for collation, then they can be rolled into a coil for storage and handling, but the adhesive properties deteriorate under temperature and humidity changes causing detachment
Solution Approach 1:
The patent replaces the chemical adhesive system with a mechanical interlocking system. T-nuts are formed with flanges that engage with slots in the backing strip, creating a mechanical connection that eliminates dependence on temperature-sensitive adhesive bonds. This mechanical substitution resolves the contradiction by providing reliable attachment that maintains stability under varying environmental conditions.
Solution Approach 2:
The invention changes the physical parameters of the connection system by transitioning from a flexible adhesive layer to a rigid mechanical interlock structure. The flange-slot engagement creates a fixed geometric relationship that maintains connection integrity regardless of temperature and humidity variations, thereby resolving the reliability issue while preserving ease of handling.
2Ease of operation
If T-nuts are collated using flexible tape, then they can be rolled into a coil, but the coil lacks structural rigidity and cannot withstand impact forces
Solution Approach 1:
The patent creates a composite structure combining the flexible coil form with a rigid backing strip. The stiff backing strip provides the necessary structural strength to withstand impact forces, while the T-nuts maintain their ability to be rolled into a coil configuration. This composite approach resolves the contradiction by integrating both flexibility for coiling and rigidity for impact resistance.
Solution Approach 2:
The invention segments the collation system into two functional components: a flexible coil structure for ease of handling and storage, and a rigid backing strip with slots for structural strength and mechanical engagement. This segmentation allows each component to optimize its specific function, resolving the contradiction between coil flexibility and impact resistance.
3Ease of manufacture
If a secondary process is used to collate T-nuts after manufacturing, then individual T-nuts can be assembled, but production time and costs increase
Solution Approach 1:
The patent merges the T-nut forming and collation operations into a single integrated process. The progressive die simultaneously forms the T-nuts and creates the flange-slot mechanical connection to the backing strip, eliminating the need for separate collation steps. This merging of operations resolves the contradiction by achieving both manufacturing flexibility and improved production efficiency.
Solution Approach 2:
The invention performs the collation action during the initial forming process itself, rather than as a subsequent operation. The flanges are formed and engaged with the backing strip slots while the T-nuts are being manufactured, preliminarily establishing the collated structure before completion. This preliminary action eliminates secondary processes and improves productivity while maintaining ease of manufacture.
Data Source
Figure 1~1A
Figure 1B~1C
Figure 1D~1E
AI summary
Apparatus for severing a T-nut from the end of a strip of T-nuts, comprising: said strip (10) of T-nuts being formed on a common strip of metal); each of said T-nuts of said strip (10) of T-nuts being integrally connected together at a frangible portion (148) with a next adjacent T-nut; each of said T-nuts includes a bore therein; a mechanism to feed and sever said strip (10) of T-nuts in endwise fashion, said mechanism includes a positioning member (53), and an endmost T-nut being in engagement with said positioning member (53); wherein said mechanism is to feed and sever said strip of T-nuts in endwise fashion, characterized by: a cutting blade (508) positioned vertically below the position of said connection portion (148) when said endmost T- Nut is in engagement with said positioning member (53); characterized in that, said mechanism to feed and sever said strip (10) of T-nuts includes a shearing ram (501) having a guide finger (60) positioned axially in line with said cylindrical bore in said endmost T-nut and adapted to move vertically from an upper to a lower position to engage said cutting blade (508) with said frangible portion (148) and sever said endmost T-nut from said strip of T-nuts.