Patent Publication Number: US-2020284288-A1

Title: Panel nut with improved retaining method

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims priority to U.S. Provisional Application No. 62/815,238, filed Mar. 7, 2019, which is hereby incorporated by reference in its entirety including the drawings. 
    
    
     TECHNICAL FIELD 
     This present specification generally relates to fasteners, and more specifically to flexible nuts that are flexibly retained on at least one panel. 
     BACKGROUND 
     Fasteners are used in a variety of applications to help secure at least two objects to one another and commonly used in manufacturing. Panel nuts are an example of these types of fasteners and are typically used as an inexpensive alternative to a conventional hex nuts when threaded loads are minimal or when space is limited. Panel nuts made of metal may be stamped and formed into the shape of a C or a U. The C or U-shape and a spring force created by the shape of panel nuts allow the panel nuts to be installed on relatively thin substrates, such as a panel. The spring force provides a small clamp load onto the panel to maintain the position of the panel nut on the panel. However, when installed onto a panel, the clamp load alone is often insufficient to maintain the position of the panel nut on the panel. This results in that the panel nut may move from its location on the panel during handling or moving the panel prior to inserting a threaded fastener. 
     Accordingly, there exists a need for an improved panel nut that better maintains its position on the article to which it is installed in advance of securing a threaded fastener to the panel nut. 
     SUMMARY 
     In one embodiment, a panel nut includes an upper arm, a lower arm, and at least one transition arm extending between the upper arm and the lower arm to allow the upper arm to elastically deflect with respect to the lower arm. The upper arm includes a forward flange, an inner member having a first end and an opposite second end, at least one outer member having a first end and an opposite second end, and a thread housing having a fastener aperture formed therein, the thread housing formed on the inner member. The first end of the inner member and the first end of the outer member extend from the forward flange. The transition arm extends between the second end of the outer member of the upper arm and the rear end of the lower arm. The lower arm includes a forward edge, an opposite rear end, a retainer hinge, and a retainer extending from the retainer hinge toward the rear end and toward the upper arm, the retainer having a retainer aperture formed therein. The retainer is configured to elastically deflect between an unstressed position and a stressed position. The retainer is at least partially received within the thread housing when in the unstressed position and the retainer does not extend within the thread housing when in the stressed position. 
     In another embodiment, a panel nut includes an upper arm, a lower arm, and a pair of transition arms extending between the upper arm and the lower arm to allow the upper arm to elastically deflect with respect to the lower arm. The upper arm includes a forward flange, an inner member having a first end and an opposite second end, a pair of outer members having a first end and an opposite second end, and a thread housing having a fastener aperture formed therein, the thread housing formed on the inner member. The first end of the inner member and the first end of the outer members extend from the forward flange. The lower arm includes a forward edge, an opposite rear end, a retainer hinge, and a retainer extending from the retainer hinge toward the rear end and toward the upper arm, the retainer having a retainer aperture formed therein. The transition arms extend between the second end of each outer member of the upper arm and the rear end of the lower arm. The retainer elastically deflects between an unstressed position and a stressed position. The retainer is at least partially received within the thread housing when in the unstressed position and the retainer does not extend within the thread housing when in the stressed position. 
     In yet another embodiment, a panel nut includes an upper arm, a lower arm, and a pair of transition arms extending between the upper arm and the lower arm to allow the upper arm to elastically deflect with respect to the lower arm. The upper arm includes a forward flange, an inner member having a first end and an opposite second end, a pair of outer members having a first end and an opposite second end, and a thread housing having a fastener aperture formed therein, the thread housing formed on the inner member. The first end of the inner member and the first end of the outer members extend from the forward flange. The lower arm includes a forward edge, an opposite rear end, a retainer hinge, and a retainer extending from the retainer hinge toward the rear end and toward the upper arm, the retainer having a retainer aperture formed therein. The retainer aperture aligns with the fastener aperture and the retainer hinge is a recess formed in the lower arm. The transition arms extend between the second end of each outer member of the upper arm and the rear end of the lower arm. The retainer elastically deflects between an unstressed position and a stressed position. The retainer is at least partially received within the thread housing when in the unstressed position and the retainer does not extend within the thread housing when in the stressed position. 
     These and additional features provided by the embodiments described herein will be more fully understood in view of the following detailed description, in conjunction with the drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The embodiments set forth in the drawings are illustrative and exemplary in nature and not intended to limit the subject matter defined by the claims. The following detailed description of the illustrative embodiments can be understood when read in conjunction with the following drawings, where like structure is indicated with like reference numerals and in which: 
         FIG. 1  schematically depicts a top rear perspective view of a panel nut; 
         FIG. 2  schematically depicts a top front perspective view of the panel nut of  FIG. 1 ; 
         FIG. 3  schematically depicts a top view of the panel nut of  FIG. 1 ; 
         FIG. 4  schematically depicts a side view of the panel nut of  FIG. 1 ; 
         FIG. 5  schematically depicts a bottom view of the panel nut of  FIG. 1 ; 
         FIG. 6  schematically depicts a perspective view of the panel nut showing a cross-section of  FIG. 1 ; 
         FIG. 7  schematically depicts a cross-sectional view of the panel nut taken along line  7 - 7  of  FIG. 2 ; 
         FIG. 8  schematically depicts a side view of the cross-section of the panel nut of  FIG. 7  with an article positioned in the panel nut when in a stressed position; and 
         FIG. 9  schematically depicts a side view of the cross-section of the panel nut of  FIG. 7  with an article positioned in the panel nut when in an unstressed position. 
     
    
    
     DETAILED DESCRIPTION 
     Embodiments described herein are directed to an improved panel nut that solves the problem of insufficient retention of a panel nut on an article or substrate, such as a panel. 
     Turning to the drawings,  FIGS. 1 and 2  illustrate an embodiment of an improved panel nut  100  that provides improved retention to an article to which it is fastened. In this embodiment, panel nut  100  includes an upper arm  115 , a lower arm  120 , and a pair of transition arms  125  extending between the upper arm  115  and the lower arm  120 . As such, the transition arms  125  extend downwardly from the upper arm  115  and connect to a respective lower arm  120 . Throughout the ensuing description, the upper arm  115  is referred to as being above the lower arm  120  for purposes of describing an “upward” direction or a “downward” direction. As shown, the upper arm  115  includes a pair of outer members  118 . However, it is to be appreciated that, in some embodiments, the upper arm  115  includes only one outer member  118 . When only a single outer member  118  is provided, only a single transition arm  125  may be provided to extend between the upper arm  115  and the lower arm  120 . 
     The panel nut  100  may be made from, for example, sheet metal. In other embodiments, the panel nut  100  may be made from a plastic, a composite, or any other suitable material. The panel nut  100  may be fabricated using conventional methods, including stamping, embossing, cutting, including laser cutting, and folding via tool and die forming methods. 
     The upper arm  115  includes a forward flange  116 , an inner member  117 , and the pair of outer members  118  having a first end  118   a  and an opposite second end  118   b . The inner member  117  includes a forward or first end  117   a  and an opposite rear or second end  117   b . The inner member  117  includes a thread housing  140 , a retainer recess  150  ( FIGS. 7 and 8 ), and a middle flange  130 . The thread housing  140  includes a thread  153  defining a fastener aperture  145 , a thread relief  155 , and an S-shaped, double conical wall  160 . The thread relief  155  is a notch formed in the conical wall  160  extending inwardly from the thread  153 . The fastener aperture  145 , the thread  153 , and the thread relief  155  cooperate to receive a threaded fastener  400  ( FIG. 8 ), such as a screw or a bolt, for securing the panel nut  100  to an article to be fastened. The conical wall  160  includes a lower bulbous cone  161  and an upper cone  165 . Throughout the ensuing description, the forward flange  116  is referred to as being forward of the transition arms  125  for purposes of describing a “forward” direction or a “rearward” direction. 
     Referring to  FIG. 4 , the pair of outer members  118  extend forwardly and downwardly from the transition arms  125  and connect to the forward flange  116  via a transition  126  at the first end  117   a  of the inner member  117 . The forward flange  116  extends from the transition  126  forwardly opposite the transition arms  125  and upwardly opposite the lower arm  120  at an angle A 1 . In some embodiments, the angle A 1  at which the forward flange  116  extends from the inner member  117  and the outer members  118  ranges from 20° to 60°. In some embodiments, the angle A 1  at which the forward flange  116  extends from the inner member  117  and the outer members  118  ranges from 30° to 50°. In some embodiments, the angle A 1  at which the forward flange  116  extends from the inner member  117  and the outer members  118  ranges from 40° to 50°. In some embodiments, the angle A 1  at which the forward flange  116  extends from the inner member  117  and the outer members  118  is 45°±5°. In other embodiments, the angle A 1  may be any other suitable angle for assisting the user to install the panel nut  100  onto an article to be fastened. 
     Referring to  FIGS. 1-4 , the forward flange  116  includes a pair of opposed corner chamfers  119  along a forward edge  121  opposite the outer members  118  for ease of installation of panel nut  100  onto an article to be fastened. The inner member  117  extends rearwardly and generally horizontally from the transition  126  toward the transition arms  125  and connects to the middle flange  130 . Referring to  FIG. 4 , the middle flange  130  extends upwardly opposite the lower arm  120  from the second end  117   b  of the inner member  117  at an angle A 2  relative to the inner member  117  and improves the rigidity and strength of the inner member  117 . In some embodiments, the angle A 2  at which the middle flange  130  extends upwardly from the inner member  117  ranges from 45° to 135°. In some embodiments, the angle A 2  at which the middle flange  130  extends upwardly from the inner member  117  ranges from 70° to 110°. In some embodiments, the angle A 2  at which the middle flange  130  extends upwardly from the inner member  117  is 90°±5°. In other embodiments, the angle A 2  may be any other suitable angle for assisting the user to install the panel nut  100  onto an article to be fastened. 
     As shown in  FIGS. 4-6 , the lower arm  120  also includes a rear flange  180 , a retainer  190  defining a retainer aperture  200 , a pair of relief slots  174 , at least one rear slot  175 , a retainer hinge  210 , and a retainer slot  220  separating the retainer  190  from the lower arm  120 . The lower arm  120  extends forwardly away from the transition arms  125  and generally horizontally with respect to the inner member  117  and is positioned under the inner member  117  and the outer members  118  of the upper arm  115 . The lower arm  120  includes a pair of opposed corner chamfers  122  along a forward edge  123 . In some embodiments, the retainer hinge  210  may include a biasing member, such as a spring, allowing the retainer  190  to bias with respect to the lower arm  120 , as discussed in more detail herein. In some embodiments, the retainer hinge  210  may be defined by a recess formed in the lower arm  120  at a point at which the retainer  190  is joined to the lower arm  120  between the relief slots  174 . 
     The rear flange  180  extends upwardly from a rear end  181  of the lower arm  120  at an angle A 3  ( FIG. 8 ) between respective outer members  118 . In some embodiments, the angle A 3  at which the rear flange  180  extends upwardly from the rear end  181  ranges from 45° to 135°. In some embodiments, the angle A 3  at which the rear flange  180  extends upwardly from the rear end  181  ranges from 70° to 110°. In some embodiments, the angle A 3  at which the rear flange  180  extends upwardly from the rear end  181  is 90°±5°. In other embodiments, the angle A 3  may be any other suitable angle for assisting the user to install the panel nut  100  onto an article to be fastened. In this embodiment, the retainer slot  220  is configured with an arcuate profile to form the retainer  190  having an arcuate retainer wall  230 . In other embodiments, the retainer slot  220  and, thus, the retainer  190 , may have any suitable geometry. 
     As shown in  FIGS. 7-9 , the panel nut  100  is configured to receive an article  300  to be fastened between the upper arm  115  and the lower arm  120 . During insertion, as shown in  FIG. 8  when in the stressed position, the upper arm  115  may be configured to deflect slightly upwardly away from the lower arm  120  via the transition arms  125  to allow the article  300  to slide between the inner member  117  of the upper arm  115  and the lower arm  120 . In this way, the transition arms  125  act as a spring to allow the inner member  117  of the upper arm  115  and the lower arm  120  to provide a clamp load on the article  300 . It should be appreciated that the inner member  117  moves independently of the outer members  118 . 
     At the same time, in the stressed position, as shown in  FIG. 8 , the retainer  190  is configured to elastically deflect downwardly and away from the upper arm  115  via the retainer hinge  210  to allow the article  300  to slide between the inner member  117  of the upper arm  115  and the lower arm  120 . The article  300  includes a fastener hole  302  that is configured to align with the fastener aperture  145 , which is coaxial with the retainer aperture  200 . Thus, when the fastener hole  302  is aligned with the fastener aperture  145  and the retainer aperture  200 , the retainer  190  is configured to elastically return to its permanently deformed positioned, i.e., an unstressed position, as shown in  FIG. 9 . To retain the article  300  between the upper arm  115  and the lower arm  120 , the arcuate retainer wall  230  of the retainer  190  is configured to lie within the fastener hole  302  of the article  300 . As such, the retainer  190  is configured to capture and retain the article  300  when positioned between the inner member  117  of the upper arm  115  and the lower arm  120 . Therefore, the retainer  190  is configured with a sizeable permanent deflection formed relative to the lower arm  120 . The sizeable permanent deflection of the retainer  190  permits the retainer  190  to firmly and positively engage the fastener hole  302  of the article  300  to prevent the panel nut  100  from sliding off of the article  300 . 
     To provide the sizable permanent deflection of the retainer  190  at the retainer hinge  210 , the thread housing  140  is configured with the double conical wall  160  to form the retainer recess  150 . The retainer recess  150  provides clearance for the retainer  190  to be significantly deflected to cause the retainer  190  to retain a sizable permanent angle relative to the lower arm  120 . As shown in  FIG. 9 , when in the unstressed position, at least a portion of an upper arcuate edge  232  defined by the arcuate retainer wall  230  and an upper retainer wall  191  of the retainer  190  is configured to be received within the thread housing  140  and lie above a bottom wall  233  of the inner member  117 . The double conical wall  160  having the lower bulbous cone  161  defining a circumference  162  of the retainer recess  150  provides the internal clearance necessary to permanently deform the retainer  190  to such a large degree. The double conical wall  160  having the upper cone  165  defining a circumference  167  causes the fastener aperture  145  and the thread  153  to be positioned above the retainer recess  150  and at a greater distance away from the lower arm  120 . This provides additional clearance for permanent deflection of the retainer  190 . As shown, the circumference  162  of the lower bulbous cone  161  is greater than the circumference  167  of the upper cone  165 . As such, the lower bulbous cone  161  has a diameter greater than a diameter of the upper cone  165 . In some embodiments, the thread  153  lies on an angular, circular wall defined by the upper cone  165 , the circumference  167 , and the fastener aperture  145 . 
     To aid in installation, the middle flange  130  and the rear flange  180  may be configured with relatively long flanges to reduce a user&#39;s installation finger pressure and, therefore, the user&#39;s installation fatigue. A middle flange  130  and the rear flange  180  reduce installation finger pressure by spreading the installation force over relatively longer flange lengths. The outer members  118  enable the middle flange  130  and the rear flange  180  to span the distance between respective outer members  118 . In some embodiments, each of the respective outer members  118  ranges from 10% to 20%±5° of the width of the lower arm  120  of the panel nut  100 . In some embodiments, each of the respective outer members  118  is 15%±5° of the width of the lower arm  120  of the panel nut  100 . In some embodiments, the middle flange  130  and the rear flange  180  each range from 40% and 60%±5° of the width of the lower arm  120 . In some embodiments, the middle flange  130  and the rear flange  180  each range from 50% to 55%±5° of the width of the lower arm  120 . Consequently, the middle flange  130  and the rear flange  180  may each be at least 50%±5° of the width of lower arm  120 . The rest of the width of the lower arm  120  is occupied by at least one rear slot  175  adjacent a respective lateral end of the rear flange  180  and the at least one transition arm  125 . In other embodiments, these widths may be any number of different percentages to make the rear slots  175  wider or narrower or to make the middle flange  130  and/or the rear flange  180  longer or shorter. Likewise, in other embodiments, the vertical height of middle flange  130  and rear flange  180  may be taller or shorter than as illustrated in the figures depending on the length of the stock from which the panel nut  100  is cut, the longitudinal placement of the thread housing  140 , and/or the vertical height of the transition arms  125 . 
     While particular embodiments have been illustrated and described herein, it should be understood that various other changes and modifications may be made without departing from the scope of the claimed subject matter. Moreover, although various aspects of the claimed subject matter have been described herein, such aspects need not be utilized in combination. It is therefore intended that the appended claims cover all such changes and modifications that are within the scope of the claimed subject matter.