Abstract:
A cage for a cage fastener includes a base and sides, with a flap integral with one side bendable to be disposed in spaced relation to the base and overlying the base. A distal edge of the flap and a distal edge of one of the sides define a cooperating locking structure whereby the position of the flap relative to the side can be secured, with a fastener positioned between the flap and the base.

Description:
CROSS REFERENCED TO RELATED APPLICATION  
       [0001]    This Non-Provisional Application claims benefit to U.S. Provisional Application Serial No. 60/353,141 filed Feb. 1, 2002. 
     
    
     
       FIELD OF THE INVENTION  
         [0002]    The present invention relates to fastening systems, and, more particularly, to encaged threaded fasteners such as a cage nut or cage bolt.  
         BACKGROUND OF THE INVENTION  
         [0003]    Caged fasteners, such as caged nuts, are used commonly in the manufacture and assembly of many items such as automobiles and other vehicles. A caged fastener can be assembled into a product framework during manufacture of a subassembly, and thereby provided in position for attachment to another subassembly during final assembly of the vehicle. The fastener can be provided in an enclosed space that otherwise would be un-accessible for positioning a fastener during final assembly.  
           [0004]    Threaded nuts are commonly provided as a caged component of a fastening system. A caged nut includes a nut enclosed in various types of structures that hold the nut in relative position, but allow for some adjustment in position for the nut during final assembly. It is advantageous to allow the nut to move in one or several directions since manufacturing tolerances and assembly tolerances frequently require some movement of the fasteners during final assembly. In a common structure for a caged nut, the encaging structure is welded or snapped to the frame, and the nut is permitted to move slightly within the cage that captures the nut.  
           [0005]    Since the integrity of the fastened joint relies on the relative security of the two components of the fastener, such as the bolt and the nut to the respective subassemblies to which they are connected, it is necessary that the retainer or encaging structure for the nut be secure. While several different structures are known, the common structural components included a base plate and a flap or flaps extending from the base plate. The flap or flaps are folded over the top of the nut, and define an opening in the top of the cage that can be aligned with the threaded opening in the nut so that a bolt may be extended there through into the nut. It is known to provide the defined opening by the flaps somewhat larger than the threaded opening in the nut, thereby allowing the nut to be moved relative to the encaging structure, with the threaded hole in the nut still being accessible. The base plate of the nut is welded to the frame or other assembly.  
           [0006]    The strength of an encaged fastener as thus described is dependent upon the strength of the encaging structure holding the nut. A problem has occurred in that some assemblies do not provided force against the top of the encaging structure, and tightening the nut and bolt can cause deflection of the flaps overlying the nut. Further, during shipment and handling of large subassemblies, the encaging structure can be bent sufficiently to release the nut held therein. If that occurs, final assembly is complicated.  
           [0007]    What is needed in the art, is an encaging structure for a cage nut that has overlying flaps that can be locked into position to retain a nut therein securely and permanently.  
         SUMMARY OF THE INVENTION  
         [0008]    The present invention provides an encaged fastener, such as a cage nut, which includes a base and a flap overlying the base defining a space there between for retaining a fastener. The flap is integral with one sidewall of the encaging structure and together with an opposite sidewall of the encaging structure defines a locking mechanisms whereby the encaging structure can be locked in an assembled position.  
           [0009]    In one aspect thereof, the present invention provides a cage nut assembly with a nut, including a body having a threaded bore, and a cage. The cage includes a base, and a first side integral with the base and having a distal edge. A second side is integral with the base and disposed substantially opposite relative to the first side on the base. A flap is integral with the second side and substantially spans the base, in spaced relation thereto. The flap has a distal edge adjacent the distal edge of the first side. The nut is disposed in the cage between the base and the flap. The distal edge of the first side and the distal edge of the flap having a cooperating locking structure for securing the flap to the first side.  
           [0010]    In another aspect thereof, the present invention provides a cage fastener assembly with a fastener having threads and a cage. The cage includes a base, a first side integral with the base and disposed at substantially right angles thereto. The first side has a distal edge. A second side substantially parallel to the first side is disposed on an opposite side of the base. The second side is integral with the base. A flap integral with the second side spans the base in spaced relation thereto. The flap has a distal edge in proximity with the distal edge of the first side. The fastener is disposed in the cage and has a portion thereof extending through the flap. The distal edge of the first side and the distal edge of the flap define a cooperating locking structure for securing the flap to the first side.  
           [0011]    In a further aspect thereof, the present invention provides a cage for a cage fastener. The cage has a base and a first side integral with the base. The first side has a distal edge including a locking member forming a first component of a cooperating locking structure. A second side is integral with the base and is disposed at an edge of the base substantially opposite to the first side. A flap is integral with the second side, and has a distal edge defining a second locking component of the cooperating locking structure. The cage is adapted for bending to bring the first and second components into locking position to secure the cage in a closed position.  
           [0012]    An advantage of the present invention is providing a cage fastener that is easy to assemble, and securely retains a fastener of a fastening system.  
           [0013]    Another advantage of the present invention is providing a cage nut that allows restricted movement of the nut during fastening of a fastening system.  
           [0014]    Still another advantage of the present invention is providing a cage fastener that elevates the fastener from the base of the encaging structure, thereby allowing paint or other coatings to be applied without adhering the fastener in a fixed position.  
           [0015]    Other features and advantages of the invention will become apparent to those skilled in the art upon review of the following detailed description, claims and drawings in which like numerals are used to designate like features. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0016]    [0016]FIG. 1 is a side elevational view of a cage fastener assembly in accordance with the present invention;  
         [0017]    [0017]FIG. 2 is a top plan view of the cage nut shown in FIG. 1;  
         [0018]    [0018]FIG. 3 is a plan view of the bottom the cage nut shown in FIGS. 1 and 2;  
         [0019]    [0019]FIG. 4 is a perspective view of the encaging structure prior to assembly of the caged nut;  
         [0020]    [0020]FIG. 5 is a top plan view similar to that of FIG. 2 but illustrating the cage nut assembly before final completion of the assembly; and  
         [0021]    [0021]FIG. 6 is a side elevational view of another embodiment of a cage fastener assembly in accordance with the present invention. 
     
    
       [0022]    Before the embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangements of the components set forth in the following description, or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or being carried out in various ways. Also, it is understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use herein of “including” and “comprising”, and variations thereof, is meant to encompass the items listed thereafter and equivalents thereof, as well as additional items and equivalents thereof.  
       DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0023]    Referring now more specifically to the drawings, and to FIG. 1 in particular, a cage fastener assembly  10  in accordance with the present invention is shown, which includes a fastener  12  and a cage  14 . Cage fastener assembly  10  illustrated in FIG. 1 is in the nature of a cage nut assembly  16 , including cage  14  and fastener  12  in the nature of a nut  18 . As illustrated in FIG. 6, cage fastener assembly  10  also can be in the form of a cage bolt assembly  20 , including cage  14  and fastener  12  in the nature of a bolt  22 . Cage fastener assembly  10  can be of different sizes and general shapes, without departing from the scope of the present invention.  
         [0024]    Fastener  12  in the nature of nut  18  (FIG. 1) includes a nut body  30  having a threaded bore portion  32 . An extended portion  34  projects outwardly of nut body  30 , and is formed integrally therewith. Bore  32  is continued through extended portion  34 , and may or may not be threaded in extended portion  34 . If unthreaded, bore  32  in extended portion  34  is of sufficient diameter to allow a threaded bolt or other fastener component (not shown) to pass there through for engagement with the threaded portion of bore  32  in nut body  30 .  
         [0025]    Fastener  12  in the nature of bolt  22  (FIG. 6) includes a bolt head body  36  and an extended threaded shank portion  38 . Shank portion  38  projects outwardly of bolt head body  36 , and may be threaded through out its length from bolt head body  36 , or may be threaded only at an end portion thereof, with an unthreaded portion adjacent bolt head body  36 .  
         [0026]    Fasteners  12  as either nut  18  or bolt  22  are common fasteners of the type, or can be specialty fastener components, as required by the specific application of cage fastener assembly  10 . Metals are suitable materials for fastener  12 , although other materials may also be suitable.  
         [0027]    Fastener  12 , as either nut  18  or as bolt  22 , is held in cage  14 , in proper position for securement with another bolt or nut, respectively. Cage  14  includes a base  40 , a first side wall  42 , a second side wall  44  and a flap or top  46 . First and second sidewalls  42  and  44  are each formed integrally with base  40 , and flap  46  is formed integrally with second sidewall  44 . In accordance with the present invention, flap  46  and first side wall  42  form separate locking components of a cooperating locking structure  48  by which cage  14  is secured in a closed position, with fastener  12  retained therein.  
         [0028]    Base  40  includes a central opening  50  with one or more weld projections  52  placed around opening  50 , by which base  40  can be secured to a surface (not shown) by welding. Other means for attaching base  40  to a surface (not shown) including, but not limited to screws, rivets, snap in features, and adhesives also can be used. Also surrounding opening  50  are a plurality of lift fingers  54 . Nut body  30  or bolt head body  36  rest on lift fingers  54 , in a slightly elevated position relative to base  40 . Liquid coatings, including paint and the like, can be applied to cage  14  and a frame or other structure to which cage  14  is attached, and will flow under fastener  12 , without adhering fastener  12  to either base  40  or the surface (not shown) to which cage  14  is attached.  
         [0029]    First and second sidewalls  42  and  44 , are formed integrally with base  40 , on opposite margins of base  40 . After bending along fold lines  56  and  58 , respectively, sidewalls  42  and  44  are at substantially right angles to base  40 . Flap  46  is positioned in spaced relation to base  40 , by bending along fold line  60 . Second sidewall  44  is a connecting web between base  40  and flap  46 , being integral with both. Flap  46  is spaced sufficiently from base  40  by sidewalls  42  and  44  to accommodated the placement of nut body  30  or bolt head body  36  between flap  46  and base  40 .  
         [0030]    It should be understood that fold lines  56 ,  58  and  60  shown in FIG. 4 are provided for the purpose of illustrating the location at which folds or bends are formed, and do not necessarily illustrate structure. The folds or bends can be formed with the use of a proper tool; however, it is also possible for creases or other formations to be used to facilitate the proper location of the bends or folds.  
         [0031]    First sidewall  42  has a distal edge  62  along which a first locking member  70  is formed. Locking member  70  is a substantially T-shaped body having a trunk  72  and an arm  74  extending outwardly from distal edge  62 . Tabs  76  and  78  are provided on opposite ends of arm  74 , outwardly of trunk  72 . Tabs  76  and  78  can be bent out of a plane defined by trunk  72 .  
         [0032]    Flap  46  defines a central aperture  80  that substantially aligns with central opening  50  of base  40  in final assembly and formation of cage fastener assembly  10 . As illustrated in FIGS.  1 - 3  and  5 , extended portion  34  of nut  18  extends from nut body  30  outwardly through central aperture  80 , slightly beyond flap  46 . Extended portion  34  is only loosely retained in aperture  80 , so that nut  18  can be moved as necessary to receive a threaded fastener (not shown) during final assembly. In cage bolt assembly  20  illustrated in FIG. 6, shank portion  38  extends from bolt head body  36  outwardly through central aperture  80 , beyond flap  46 . Shank portion  38  is only loosely retained in aperture  80 , so that bolt  22  can be moved as necessary to receive a threaded fastener (not shown) during final assembly.  
         [0033]    At an outer margin portion thereof, near a distal edge  82  of flap  46 , a slot  84  is defined through flap  46 . Slot  84  is of sufficient length and width that locking member  70  can be inserted there through. However, slot  84  is not significantly larger then necessary to receive locking member  70 , so that slight bending of tabs  76  and  78  prevents retraction of locking member  70  from and through slot  84 . While tabs  76  and  78  are illustrated to be bent in the same direction, i.e. toward central aperture  80 , it should be understood that the flaps also can be bent in opposite directions, one toward and one away from central aperture  80 , or can be both bent in a direction generally away from central aperture  80 .  
         [0034]    Advantageously, cage  14  is provided as a one-piece structure formed by stamping or the like from sheet material such as metal (FIG. 4). The stamped blank  90  is bent into the final shape of cage  14 , as shown in the drawings.  
         [0035]    To assemble cage fastener assembly  10  with nut  18 , blank  90  is formed by a stamping or cutting operation from a piece of sheet material, such as steel or other metal. Blank  90  is bent at fold lines  56  and  58  to form substantial right angles between first side wall  42  and base  40 , and between second side wall  44  and base  40 . At this stage, partially assembled cage  14  can be attached to a frame or other structure by welding in the locations of weld projections  52 . Other attachment schemes can be used, and attachment can be delayed until after a fastener  12  is installed in cage  14 .  
         [0036]    Nut  18  is positioned with extended portion  34  in central aperture  80 , as a further bend is made at fold line  60 . As distal edge  82  of flap  46  approaches distal edge  62  of first sidewall  42 , arm  74  of locking member  70  is positioned to slide through slot  84 . As an underside of flap  46  is brought into substantial contact with distal edge  62 , arm  74  will have passed completely through slot  84 . Thereafter, tabs  76  and  86  are bent to prevent retraction of arm  74  through slot  84 . Nut body  30  is restrained between base  40  and flap  46 , and rests on lift fingers  54  in an elevated position with respect to base  40 . Extended portion  34  projects loosely through central aperture  80 , holding nut  18  in cage  14 , but allowing some movement and repositioning of nut  18  relative to cage  14  so that nut  18  can be aligned properly with a fastener to be connected therewith.  
         [0037]    If a cage bolt assembly  20  is to be formed, the procedure is essentially the same as that described above for cage nut assembly  16 . Shank portion  38  of bolt  22  is positioned in central aperture  80  of flap  46 , and bolt head body  36  rests on lift fingers  54 .  
         [0038]    With tabs  76  and  78  of arm  74  bent so as to be in nonalignment with slot  84 , cage  14  is securely held in the assembled position. Flap  46  can not be moved inadvertently relative to base  40 . Further, as caged fastener  12  is tightened relative to a cooperating fastener (not shown), cage  14  remains closed, and fastener  12  is retained in its proper position.  
         [0039]    Variations and modifications of the foregoing are within the scope of the present invention. It is understood that the invention disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text and/or drawings. All of these different combinations constitute various alternative aspects of the present invention. The embodiments described herein explain the best modes known for practicing the invention, and will enable others skilled in the art to utilize the invention. The claims are to be construed to include alternative embodiments to the extent permitted by the prior art.  
         [0040]    Various features of the invention are set forth in the following claims.