Patent Description:
Nut plate assemblies are discrete fittings fastened onto a component or part to threadably attach the component or part to other components, parts, structures, etc. Often nut plates facilitate assembly of parts to be joined and also disassembly of joined parts, such as may be required, for inspection or replacement of parts, etc. In nut plate assemblies, the threaded nut portion is incorporated into and/or is surrounded by an elongated portion or plate, the entire structure of which acts as the nut element in the fastener assembly. The nut element is positioned, often loosely, into a cradle element dimensioned to receive the nut element. The nut element and the cradle, together, are typically referred to as the "nut plate" or "nut plate assembly". Typically, nut plates are fastened to a part that is to be later joined to another part, or to a larger structure. Nut plates are physically joined, via rivets, into desired joining positions on a part. In this way, riveted nut plates are in position on a part, often in advance of further assembly of the part having the nut plate to another part.

Such rivet installation further requires that holes must be drilled with precision and often countersunk to allow an installed rivet to be substantially "flush" with a part surface after rivet installation. Such countersinking, if performed incorrectly can increase part waste, and the drilling itself, even if performed correctly, is labor-intensive further resulting in increased overall cost.

To retain the nut plate in position on a part, holes are drilled through a part from a first side of the part. The nut plate is then positioned such that the holes in the nut plate align with the drilled holes. A retention tool, such as a "cleco", is used to temporarily assist in positioning sheets of material together, or to pieces such as stiffeners before the pieces are permanently joined. Clecos are installed in holes predrilled through the workpieces. Usually such holes are intended for permanent fasteners installed later. The cleco expands on the far side of the workpieces and then draws and clamps the nut plate to the part temporarily while maintaining the desired alignment. Clecos prevent shifting of the workpieces and maintain the alignment of other "open" fastener holes that do not have clecos inserted in them (e.g. holding the nut plate in position relative to the component and keeping the holes in the component and the cradle element of the nut plate aligned.

Typically, nut plates are installed into a structure when only one side of the structure will be easily accessible, or "open" for accepting tools (e.g., with respect to ease of securing the component to the structure with a fastening tool or tools), and where components are to be attached to the structure after the structure is in an installed orientation, and where at least one side of the structure is less accessible, or "closed". Aircraft and other vehicular structures present a particular application for the use of nut plates. Typically, the nut portion in a nut plate assembly is initially oriented in a nut plate cradle, or basket component, and the entire nut plate assembly is positioned on the interior, or "blind side" or "closed side" of a component. Once the nut plate is in position, the nut plate assembly is then securely affixed to the structure via rivets that are driven through the first side of the part, then into and through the nut plate.

In some nut plate assemblies, the nut is allowed to move slightly after installation, or "float", allowing for the nut to move slightly and accurately align with the bolt (that is to engage the nut). Across a typical aircraft, for example, joined structures may require the installation of thousands of nut plate assemblies, requiring the installation of thousands of rivets to secure the nut plate assemblies. Each nut plate installation therefore requires the procurement and use of special alignment tools (drills, clecos, etc.) followed by riveting operations that also require special tools. Therefore, nut plate installations result in a labor-intensive and time-consuming endeavor performed by skilled technicians that adds significant time and cost to the manufacture of such large structures, as well as adding to the total number of parts that must be maintained in inventory, while also adding steps and complexity to assembly protocols. Further, the presence of multi-part nut plate assemblies, and the rivets required to install such assemblies, adds significant overall weight to a large structure.

<CIT>, according to its abstract, states that it relates to a fastening element for fastening in components which has at least one cavity being integrally formed within an inner region of the fastening element; and at least one deflection portion being integrally formed at a surface region of the fastening element proximate to the at least one cavity; wherein the deflection portion is configured to resiliently deform into the cavity upon application of external forces to the deflection portion. A fastening assembly has such a fastening element; and an engagement component with a fastening hole; wherein the fastening hole is shaped to engage with the fastening element upon insertion of the fastening element into the fastening hole by resiliently deforming the at least one deflection portion into the at least one cavity. A method for manufacturing such a fastening element includes manufacturing a fastening element with at least one cavity and at least one deflection portion using an additive manufacturing or 3D printing technique.

<CIT>, according to its abstract, states that it relates to a spiral fastener, which may be made of layers of material and/or a light curable material. It is proposed to use a three-dimensional printing machine to emit material from an ink jet printing head to build up a fastener having a spiral formation.

<CIT>, according to its abstract, states that it relates to a repair/replacement nut plate assembly, which is fully preassembled, is provided which can be inserted into an oversized or reworked/reconditioned aperture of a workpiece after an original nut plate has been removed from the original aperture of the workpiece. The repair/replacement nut plate assembly includes a nut, a holding bracket, a stem, a nut retainer, and a sleeve member. The sleeve member is configured to be secured to a nut plate assembly, of the same type originally used to provide the original nut plate in the original aperture of the workpiece to compensate for material lost from the workpiece during the removal of the original nut plate. The sleeve member is aimed at allowing utilizing the original nut plate assembly with only the securement of the sleeve member to the holding bracket prior to setting.

<CIT>, according to its abstract, states that it relates to a fastener made of layers of material, a light curable material and/or multiple built-up materials. Another aspect uses a three-dimensional printing machine to emit material from an ink jet printing head to build up a fastener.

The scope of protection is defined in the appended independent claims. Optional embodiments are claimed in the dependent claims.

Aspects of the present disclosure are directed to additively manufactured parts comprising features of a nut plate assembly additively manufactured integrally into the part additively manufactured as defined in claim <NUM>-<NUM>, and methods of their manufacture as defined in claims <NUM>-<NUM>, installation of the additively manufactured parts, and larger structures comprising the additively manufactured parts as defined in claim <NUM>.

In the step of using an additive manufacturing process to construct a part, the part may comprise a non-metallic material, with the non-metallic material including one or more of a thermoset plastic material; a thermoplastic material; a composite material; a ceramic material; a carbon-fiber containing material; a boron fiber-containing material; a glass fiber-containing material; an aramid fiber-containing material; polytetrafluoroethylene; polyethylene terephthalate; glycol modified polyethylene terephthalate; and combinations thereof.

In the step of using an additive manufacturing process to construct a part, the part may comprise a metallic material, with the metallic material including one or more of titanium; a titanium alloy; steel; aluminum; an aluminum alloy; cobalt; a cobalt alloy; bronze; copper; a copper alloy; and combinations thereof.

In the step of forming a nut-retaining cradle, the nut-retaining cradle may be dimensioned to orient a nut.

A further aspect of the present disclosure is directed to a component comprising an additive manufactured part, with the part comprising additive manufactured nut-retaining cradle integral with the additive manufactured part, with the nut-retaining cradle comprising a cradle bed and at least one cradle wall, with the cradle wall extending substantially perpendicularly from the cradle bed and extending to a predetermined distance from the cradle bed, and wherein the cradle wall comprises at least one integral cradle wall nut-retaining feature, with the integral cradle wall nut-retaining feature configured to receive a retainer, with the retainer configured to engage the integral cradle wall nut retaining feature, and with the integral cradle wall nut-retaining feature further configured to establish a restricted range of movement for a nut retained in the nut-retaining cradle along at least one axis.

A further aspect is directed to a structure comprising the component.

In another aspect, the structure comprises a stationery structure.

In a further aspect, the structure comprises a vehicle.

In another aspect, the vehicle includes one or more of a manned aircraft; an unmanned aircraft; a manned spacecraft, an unmanned spacecraft, a manned rotorcraft, an unmanned rotorcraft, a manned terrestrial vehicle, an unmanned terrestrial vehicle, a manned surface waterborne vehicle, an unmanned surface water-borne vehicle; a manned sub-surface water-borne vehicle, an unmanned sub-surface water-borne vehicle, a satellite, a rocket, a missile, and combinations thereof.

Another aspect is directed to a method for installing a joining assembly comprising joining an additively manufactured part to a nut, with the part comprising an additively manufactured nut-retaining cradle integral with the additively manufactured part, with the nut-retaining cradle dimensioned to receive the nut and a nut retainer, positioning the nut retainer in the nut-retaining cradle, and. installing the joining assembly.

In a further aspect, the nut plate is a rivetless nut plate.

A further aspect is directed to a method for joining parts comprising joining an additively manufactured part to a nut, with the part comprising an additively manufactured nut-retaining cradle integral with the additively manufactured part, with the nut-retaining cradle dimensioned to receive the nut and a nut retainer, positioning the nut retainer in the nut-retaining cradle, and joining the part to another part.

A further aspect is directed to a method for joining a part to a structure comprising joining an additively manufactured part to a nut, with the part comprising an additively manufactured nut-retaining cradle integral with the additively manufactured part, with the nut-retaining cradle dimensioned to receive the nut and a nut retainer, positioning the nut retainer in the nut-retaining cradle, and joining the part to a structure.

The features, functions and advantages that have been discussed can be achieved independently in various aspects or may be combined in yet other aspects further details of which can be seen with reference to the following description and the drawings.

Aspects of the present disclosure are directed to additively manufactured parts comprising integral features of a nut plate assembly; particularly an integral nut-retaining cradle, and methods for their manufacture.

According to further aspects of the present disclosure, methods are disclosed that obviate the need for rivets or drilling holes for rivet that would need to be carefully countersunk so as to allow an installed rivet to be substantially "flush" with a part surface after rivet installation.

As shown in <FIG>, a method <NUM> is disclosed comprising using <NUM> an additive manufacturing process to construct an additively manufactured part. Such additive manufacturing processes or "3D manufacturing" processes can be used to progressively deposit extremely thin layers of material to create an three-dimensional object from a computer assisted drawing (CAD) file or file formats that include Additive Manufacturing file (AMF) format. Additive manufacturing (AM) is understood as referring to processes used to create a three-dimensional (3D) object where layers of material are formed, typically under computer control, to create an object. Objects can be of almost any shape or geometry and are produced using digital model data from a 3D model or another electronic data source such as an AMF format. Therefore, compared to removing material from a stock piece, as may be done in a conventional machining process to form a part, 3D printing or AM builds a three-dimensional object from a computer-aided design (CAD) model or an AMF or STL file format by successively adding material layer-by-layer to accurately produce a part having a desired and/or predetermined dimension and/or geometry. As shown in <FIG>, a method is disclosed further comprising forming <NUM> an additively manufactured nut-retaining cradle integrally with the part using additive manufacturing of the part and the integrally formed and additively manufactured nut-retaining features.

The term "3D printing" originally referred to a process that deposits a binder material onto a powder bed with inkjet printer inkjet printer heads layer-by-layer. More recently, the term is being used in popular vernacular to encompass a wider variety of additive manufacturing techniques. United States and global technical standards use the term "additive manufacturing" in this broader sense. For example, standard ISO/ASTM52900-<NUM> defines seven categories of AM processes within its meaning: binder jetting, directed energy deposition, material extrusion, material jetting, powder bed fusion, sheet lamination and vat photopolymerization.

As a result, it is contemplated that the use of many additive manufacturing processes are known for depositing metallic and non-metallic materials to form an additive manufactured product. A non-exhaustive list of such processes includes, without limitation, direct energy deposition; direct metal laser sintering; direct metal printing; electron beam additive manufacturing; electron beam melting; electron beam powder bed manufacturing; fused deposition modeling; indirect powder bed manufacturing; laser cladding; laser deposition manufacturing; laser deposition welding; laser deposition welding/integrated milling; laser engineering net shaping; laser freeform manufacturing; laser metal deposition with powder; laser metal deposition with wire; laser powder bed manufacturing; laser puddle deposition; laser repair manufacturing; powder directed energy deposition; stereolithography; selective laser melting; selective laser sintering; small puddle deposition; or combinations thereof.

Therefore, a large number of additive processes are available. The main differences between processes are in the way layers are deposited to create parts and in the materials that are used. Some methods melt or soften the material to produce the layers. For example, in fused filament fabrication, also known as fused deposition modeling (FDM), the part is produced by extruding small beads or streams of material which harden immediately to form layers. A filament of thermoplastic material, or metal in the form of metal wire, or other material is fed into an extrusion nozzle head (e.g. a 3D printer extruder), that heats the material and produces a deposit material flow. Another technique fuses parts of the layer and then moves "upward" in the working area, adding successive layers of granules, and repeating the process until the piece has "built up". This process uses the unfused media to support overhangs and thin walls in the part being produced, reducing the need for temporary auxiliary supports for the piece.

Laser sintering techniques include, without limitation, selective laser sintering with both metals and polymers, and direct metal laser sintering. Selective laser melting does not use sintering for the fusion of powder granules, but will completely melt the powder using a high-energy laser to create fully dense materials in a layer-wise deposition method that has mechanical properties similar to those of conventional manufactured metals. Electron beam melting is a similar type of additive manufacturing technology for metal parts (e.g. titanium, titanium alloys). EBM manufactures parts by melting metal powder layer by layer with an electron beam in a high vacuum. Another method consists of an inkjet 3D printing system that creates the part one layer at a time by spreading a layer of powder (plaster or resins) and printing a binder in the cross-section of the part using an inkjet-like process. With laminated object manufacturing, thin layers are cut to shape and joined together.

Other methods cure liquid materials using different sophisticated technologies, such as sterolithography. Photopolymerization is primarily used in stereolithography to produce a solid part from a liquid. Inkjet printer systems like the Objet PolyJet system spray photopolymer materials onto a build tray in ultra-thin layers (e.g., between <NUM> and <NUM>) until the part is completed. Each photopolymer layer is cured with UV light after it is jetted, producing fully cured models that can be handled and used without post-curing. Further, ultrasmall features can be made with the 3D micro-fabrication technique used in multiphoton photopolymerization. Due to the nonlinear nature of photo excitation, a gel is cured to a solid only in the places where the laser was focused while the remaining gel is removed. Feature sizes of under <NUM> can be produced, as well as complex structures that can comprise moving and interlocked parts.

Yet another approach uses a synthetic resin that is solidified using LEDs. In Mask-image-projection-based stereolithography, a 3D digital model is sliced by a set of horizontal planes. Each slice is converted into a two-dimensional mask image. The mask image is then projected onto a photocurable liquid resin surface and light is projected onto the resin to cure it in the shape of the layer. Continuous liquid interface production begins with a reservoir of liquid photopolymer resin. Part of the reservoir is transparent to ultraviolet light, causing the resin to solidify.

In powder-fed directed-energy deposition, a high-power laser is used to melt metal powder supplied to the focus of the laser beam. The powder fed directed energy process is similar to Selective Laser Sintering, but the metal powder is applied only where material is being added to the part at that moment.

<FIG> is a perspective view of an aspect of the present disclosure showing an additively manufactured part <NUM> comprising an additively manufactured integral nut-retaining cradle <NUM>. The integral nut-retaining cradle <NUM> comprises an integral cradle bed <NUM> and integral cradle walls <NUM> and <NUM> extending a predetermined distance from integral cradle bed <NUM> with the integral cradle walls <NUM>, <NUM> built via additive manufacturing and oriented substantially perpendicular to the integral cradle bed <NUM>. According to one aspect as shown, integral cradle bed <NUM> defines an opening 22a defined and bounded by integral cradle bed <NUM> and part <NUM> and extending through the integral cradle bed <NUM> and through integral part <NUM>. Integral cradle walls <NUM>, <NUM> comprise through-slots <NUM>, <NUM>, respectively. Through-slots <NUM>, <NUM> are understood to extend from integral cradle wall inner surfaces 23a, 24a through the thickness of integral cradle walls <NUM>, <NUM> to integral cradle wall outer surfaces 23b, 24b, respectively. Integral cradle bed <NUM> as shown in <FIG> further comprises integral cradle bed nut-retaining features 27a, 27b extending (e.g., in a "raised" fashion) a predetermined distance from, and with respect to, integral cradle bed <NUM>.

<FIG> is a perspective view of an aspect of the present disclosure showing an additively manufactured part <NUM> with all numbered aspects similar to those shown in <FIG>, with the exception that the opening 22a is absent. That is, in the aspect of the disclosure illustrated in <FIG>, there exists no opening 22a defined and bounded by integral cradle bed <NUM> and part <NUM> and extending through the integral cradle bed <NUM> and through integral part <NUM> as shown in <FIG>. According to this aspect, the additively manufactured integral nut-retaining cradle is printed without opening 22a. It is to be understood that an opening may later be drilled after printing, for example, as a post-processing operation.

<FIG> is a perspective view of an aspect of the present disclosure showing the additively manufactured part <NUM> of <FIG> further comprising nut <NUM> inserted proximate to integral nut-retaining cradle <NUM> and resting on integral cradle bed <NUM> and bounded on two sides by integral cradle walls <NUM>, <NUM>. Nut depression 28a is shown resting proximate to integral cradle bed nut-orienting feature 27a. As shown in <FIG>, nut depression 28b does not rest immediately proximate to integral cradle bed nut-orienting feature 27b. In this way, as illustrated in <FIG>, nut <NUM> is allowed to move or "float" slightly while being retained proximate to integral cradle bed <NUM>.

Nut <NUM> is allowed to move slightly or "float" in a direction substantially parallel to the integral cradle walls <NUM>, <NUM> within integral cradle bed <NUM>, but is restricted from moving excessively in such direction before impacting, and being restricted in movement in such direction by, integral cradle bed nut-orienting features 27a, 27b. Retainer <NUM> is shown in <FIG> and <FIG> as resting proximate to nut <NUM> with retainer section 29a engaging through-slot <NUM> of integral cradle wall <NUM> and retainer section 29b engaging through-slot <NUM> of integral cradle wall <NUM>. Retainer ends 29c and 29d are dimensioned and/or geometrically configured to impact integral cradle walls <NUM>, <NUM> respectively, and retain nut <NUM> proximate to internal cradle bed <NUM>. That is, the predetermined dimension and/or geometry of retainer <NUM> is such that retainer <NUM> remains in position in the integral nut-retaining cradle <NUM> and proximate to the nut <NUM>, thus retaining the nut <NUM> in the integral nut-retaining cradle <NUM>.

The geometric shape of retainer <NUM>, as shown in <FIG> and <FIG> is an "open" or "discontinuous" rectangular shape. The geometric orientation and predetermined dimension of the retainer <NUM> enables the retainer <NUM> to remain in position proximate to nut <NUM>, and serves to hold or retain nut <NUM> in a predetermined orientation within the integral nut-retaining cradle <NUM>. That is, the dimension of the retainer <NUM> is such that, when retainer section 29a of retainer <NUM> engages through-slot <NUM> of integral cradle wall <NUM> and retainer section 29b of retainer <NUM> engages through-slot <NUM> of integral cradle wall <NUM>, the retainer <NUM> is able to maintain a relative desired and predetermined position that retains nut <NUM> in a desired and predetermined location in the integral cradle <NUM>, and substantially proximate to integral cradle bed <NUM>, even though nut <NUM> may be allowed to move slightly, or "float", a predetermined distance within the integral cradle bed <NUM> in the direction substantially parallel to the integral cradle walls <NUM>, <NUM> and/or move or "float" a slight predetermined distance in the direction substantially perpendicular to the integral cradle walls <NUM>, <NUM>. This "floating" movement of the nut <NUM> relative to its position within the nut-retaining cradle <NUM> allows the nut <NUM> to move slightly within the nut-retaining cradle in a manner required of a nut in a nut plate assembly during the alignment of the nut that will take place, for example, during a fastening operation, such as when a mating fastener is introduced into the nut as the part <NUM> is fastened to another part, component, structure, etc. As further shown in <FIG>, <FIG>, <FIG>, and <FIG>, the integral cradle bed <NUM> additively manufactured integrally with the additively manufactured part <NUM> is shown as being "raised" a predetermined distance from the part surface 20a of the part <NUM>, to create and include an integral nut-retaining cradle raised base 21a (as shown in <FIG> and <FIG>). The thickness of the base can be tailored and additively manufactured integrally with the part as desired and in a predetermined fashion to impart a required or desired robustness in terms of reinforcing an area of a part placed under added stress at locations where the part is to be joined to other parts, components, structure, etc..

<FIG> is an enlarged perspective view of an additively manufactured part <NUM> comprising an integral and additively manufactured nut-retaining cradle <NUM>. As shown in <FIG>, the integral nut-retaining cradle 41comprises an integral cradle bed <NUM> and integral cradle walls <NUM> and <NUM> extending a predetermined distance from integral cradle bed <NUM> with the integral cradle walls <NUM>, <NUM> built via additive manufacturing and oriented substantially perpendicular to the integral cradle bed <NUM>. According to one aspect as shown in <FIG>, integral cradle bed <NUM> defines an integral cradle bed opening (not shown or visible in <FIG>) extending through the integral cradle bed <NUM> and through integral part <NUM>. According to an alternate aspect, integral nut-retaining cradle <NUM> may be additively manufactured with part <NUM> without an integral cradle bed opening, if desired. Integral cradle walls <NUM>, <NUM> comprise through-slots <NUM>, <NUM>, respectively through cradle walls <NUM>, <NUM>. Through-slots <NUM>, <NUM> are understood to extend from integral cradle wall inner surfaces 43a, 44a through the thickness of integral cradle walls <NUM>, <NUM> to integral cradle wall outer surfaces 43b, 44b, respectively. Integral cradle bed <NUM> as shown in <FIG> further comprises integral cradle bed nut-retaining features 47a, 47b extending a predetermined distance from integral cradle bed <NUM>, or in a "raised" fashion with respect to the integral cradle bed <NUM>. Integral cradle bed <NUM> as shown in <FIG> differs from integral cradle bed <NUM> shown in <FIG>, <FIG>,<FIG> , and <FIG> in that the integral cradle bed <NUM> is not "raised " from the surface of the part <NUM>. As shown in <FIG>, integral cradle bed surface <NUM> is substantially flush with part surface 40a of part <NUM>.

Retainer <NUM> is shown in <FIG> as positioned proximate to nut <NUM> with retainer section 49a engaging through-slot <NUM> of integral cradle wall <NUM> and retainer section 49b engaging through-slot <NUM> of integral cradle wall <NUM>. Retainer ends 49c and 49d are dimensioned and/or geometrically configured to impact integral cradle walls <NUM>, <NUM> respectively. That is, the predetermined dimension and/or geometry of retainer <NUM> is such that retainer <NUM> remains in position in the integral nut-retaining cradle <NUM> and proximate to the nut <NUM>, thus retaining the nut <NUM> in the integral nut-retaining cradle <NUM>.

As shown in <FIG>, integral cradle walls <NUM>, <NUM> are shown comprising a non-uniform, or varying wall thickness along their length. The predetermined dimension and predetermined geometry of the integral cradle walls, as well as the entire cradle, are tailored to achieve a desired and predetermined degree of robustness relative to required or desired structural performance of the additively manufactured part comprising the integral additively manufactured integral cradle walls. According to an aspect, the cradle walls assist in withstanding physical forces sustained during a fastening operation of a part during part installation, as a fastener dimensioned to securely mate with the nut engages the nut and proceeds during a fastening operation to a desired tightness. Such forces include, for example and without limitation, torque, material stresses, material fatigue, etc. Further, the material (e.g. metallic-containing material, non-metallic-containing material) used to make the additively manufactured part may further impact the useful dimensions and geometry of the integral cradle bed and its attendant additively manufactured features.

<FIG> is a further perspective view of an additively manufactured part comprising an aspect of the present disclosure showing an additively manufactured part <NUM> comprising an integral additively manufactured nut-retaining cradle <NUM>. The nut-retaining cradle 51comprises an integral cradle bed <NUM> and integral cradle walls <NUM> and <NUM> extending a predetermined distance from integral cradle bed <NUM> with the integral cradle walls <NUM>, <NUM> built via additive manufacturing and oriented substantially perpendicular to the integral cradle bed <NUM>. According to one aspect as shown, integral cradle bed <NUM> defines an opening 52a extending through the integral cradle bed <NUM> and through integral part <NUM>. According to an alternate aspect (not shown in <FIG>), integral nut-retaining cradle <NUM> may be additively manufactured with part <NUM> without an integral cradle bed opening 52a, if desired. Integral cradle walls <NUM>, <NUM> comprise through-slots <NUM>, <NUM>, respectively. Through-slots <NUM>, <NUM> are understood to extend from integral cradle wall inner surfaces 53a, 54a through the thickness of integral cradle walls <NUM>, <NUM> to integral cradle wall outer surfaces 53b, 54b, respectively.

Integral cradle bed <NUM>, as shown in <FIG>, further comprises integral cradle bed nut-retaining features 57a, 57b extending a predetermined distance from integral cradle bed <NUM>, or in a "raised" fashion with respect to the integral cradle bed <NUM>. As with the integral cradle bed <NUM> shown in <FIG>, integral cradle bed <NUM> as shown in <FIG> also differs in configuration from the integral cradle bed <NUM> shown in <FIG>, <FIG>, <FIG> and <FIG>, in that the integral cradle bed is not "raised" to any predetermined distance from and/or "above" the part surface 50a. In other words, as shown in <FIG>, integral cradle bed <NUM> is additively manufactured integrally with part <NUM> to remain substantially flush with part surface 50a of part <NUM>.

Retainer <NUM> is shown in <FIG> as positioned proximate to nut <NUM> with retainer section 59a engaging through-slot <NUM> of integral cradle wall <NUM> and retainer section 59b engaging through-slot <NUM> of integral cradle wall <NUM>. Retainer ends 59c and 59d are dimensioned and/or geometrically configured to impact integral cradle walls <NUM>, <NUM> respectively. In an aspect, the predetermined dimension and/or geometry of retainer <NUM> is such that retainer <NUM> remains in position in the integral cradle bed <NUM> of integral nut-retaining cradle <NUM> and proximate to the nut <NUM>, thus retaining the nut <NUM> in the integral nut-retaining cradle <NUM>.

As shown in <FIG>, <FIG>, <FIG>, the geometric shape of retainers <NUM>, <NUM>, <NUM> is "open" or "discontinuous" rectangular shape. The geometric orientation and/or predetermined dimension of the retainer enables the retainer to remain in position proximate to, and serving to hold or retain nut <NUM>, <NUM>, <NUM> respectively in a predetermined orientation within the integral nut-retaining cradle <NUM>, <NUM>, <NUM> respectively. That is, according to aspects as shown in <FIG>, <FIG>, <FIG>, the dimension of the retainer is such that, when retainer sections 29a, 49a, 59a of retainers <NUM>, <NUM>, <NUM> engage the respective through-slots of integral cradle walls, the retainers are able to maintain a position that retains a nut <NUM>, <NUM>, <NUM> in a desired and predetermined approximate yet definable overall location in the integral cradle <NUM>, <NUM>, <NUM>, and substantially proximate to integral cradle bed <NUM>, <NUM>, <NUM>, even though a nut may be allowed to move slightly, or "float" a predetermined distance within the integral cradle bed in the direction substantially parallel to the integral cradle walls, and move or "float" a slight predetermined distance in the direction substantially perpendicular to the integral cradle walls.

According to further aspects of the present disclosure, the geometric shape of the retainer may be continuous, or "closed". In such a continuous configuration, a retainer would not comprise retainer "ends" as shown in <FIG>, <FIG>, <FIG>, but sections of the retainer would still adequately engage through slots in the integral cradle walls. Further aspects contemplate a retainer having a suitable and predetermined dimension and geometry to exert sufficient and predetermined outward force such that the retainer would remain in position between integral cradle walls while retaining a nut in a desired and/or predetermined location proximate to the integral cradle bed.

According to further aspects, to assist a substantially fixed positioning of the retainer between the integral cradle walls, the inner surfaces of the cradle walls may comprise recesses dimensioned to receive sections of the retainer. The predetermined outward force of the retainer, forces section of the retainer to engage and otherwise "seat" into the recesses in the integral cradle wall inner surfaces. In an aspect, such recesses may be substantially linear in the form of a recessed groove or grooves substantially parallel with the lengthwise direction of the respective cradle wall. However, further aspects contemplate any form of recess able to engage and retain a section of the retainer for the purpose of retaining the nut in a predetermined position proximate to the integral nut-retaining cradle. Such recesses include, without limitation dimples, or any type of depression formed integrally or later machined into the surfaces of the integral nut-retaining cradle walls. Still further, aspects of the present disclosure contemplate additively manufactured features that may protrude from the inner wall surfaces or outer wall surfaces of the integral nut-retaining cradle walls to facilitate positioning and retention of a nut in the integral nut-retaining cradle. Further aspects contemplate such recesses or protrusions engaging directly with a feature or features of the nut itself, thus obviating or being used in concert with a retainer to facilitate positioning and retention of a nut in the integral nut-retaining cradle. Still further aspects contemplate any form of recess able to engage and retain a section of the retainer for the purpose of retaining the nut in a predetermined position proximate to the integral nut-retaining cradle, including recesses that comprise recess portions that pass completely through the integral cradle walls.

The retainers may be made from any useful material including, without limitation, metal-containing and non-metal-containing materials. Since the intended function of the retainer essentially ceases upon the insertion and tightening of a mating fastener dimensioned to engage with the nut, such retainer material may be selected based on weight, cost etc., without regard for any particular material robustness relative to particular strength or ability to sustain any particular load or stress.

<FIG> are overhead plan perspective views of aspects according to the present disclosure illustrating non-limiting and non-exhaustive representative geometries and dimensions for retainers used in conjunction with additively manufactured integral nut-retaining cradles additively manufactured integrally with a part. Therefore, <FIG> show additively manufactured parts comprising an aspect of the present disclosure, and showing manufactured nut-retaining cradles 61a, 61b, 61c, 61d, 61e, and 61f that are understood as being integral with an additively manufactured part (not shown); the parts being similar to those shown in <FIG>, <FIG>, <FIG>, <FIG>, <FIG>.

As shown in <FIG>, nut-retaining cradle 61a comprises an integral cradle bed 62a and integral cradle walls 63a and 64a extending a predetermined distance from integral cradle bed 62a with the integral cradle walls 63a, 64a built via additive manufacturing and oriented substantially perpendicular to the integral cradle bed 62a. According to one aspect as shown in <FIG>, integral cradle bed 62a defines an opening 62a' extending through the integral cradle bed 62a and through the additively manufactured integral part (not shown). According to an illustrated aspect, integral cradle walls 63a, 64a comprise recesses 65a, 66a that do not extend all the way through integral cradle walls 63a, 64a respectively. As shown, recesses 65a, 66a extend from integral cradle wall inner surfaces to a predetermined distance into the integral cradle walls 63a, 64a respectively. Integral cradle bed 62a as shown in <FIG> further comprises integral cradle bed nut-orienting features 67a', 67a" extending a predetermined distance from integral cradle bed 62a, or in a "raised" fashion with respect to the integral cradle bed 62a.

As shown in <FIG>, retainer 69a is shown positioned proximate to nut 68a with retainer section 69a' inserted into and engaging recess 65a of integral cradle wall 63a and retainer section 69a" inserted into and engaging recess 66a of integral cradle wall 64a. In an aspect, the predetermined dimension and/or geometry of retainer 69a is such that retainer 69a remains in position in the integral nut-retaining cradle 61a and proximate to the nut 68a, thus retaining the nut 68a in the integral nut-retaining cradle 61a. <FIG> show various alternate and non-exhaustive geometries and/or dimensions for retainers and/or recesses in the integral nut-retaining cradle 61a used to retain nut 68a as shown in <FIG>.

<FIG> shows the retainer 69a (shown in <FIG>) positioned proximate to nut 68a with retainer section 69a' inserted into and engaging recess 65b of integral cradle wall 63b and retainer section 69a" inserted into and engaging recess 66b of integral cradle wall 64b. In an aspect as shown in <FIG>, the predetermined dimension and/or geometry of retainer 69a is such that retainer 69a remains in position in the integral nut-retaining cradle 61a and proximate to the nut 68a, thus retaining the nut 68a in the integral nut-retaining cradle 61a. However, as shown in <FIG>, the recesses 65b and 66b are configured and additively manufactured to a dimension and/or geometry that more closely matches or otherwise more closely approximates the dimension and/or geometry of sections 69a' and 69a" of retainer 69a. The remainder of the features shown in <FIG> (but not enumerated) is understood to be those shown in <FIG>.

<FIG> show further aspects of the present disclosure where multiple retainers are shown positioned proximate to nut 68a. In <FIG>, the nut-retaining function is accomplished via the predetermined placement of two retainers 69c' and 69c". As shown, a first end of retainer 69c' engages recess 65c of integral cradle wall 63c, and a second end of retainer 69c' engages recess 66c of integral cradle wall 64c. In addition, as shown in <FIG>, a first end of retainer 69c" engages recess 65c of integral cradle wall 63c, and a second end of retainer 69c" engages recess 66c of integral cradle wall 64c. The remainder of the features shown in <FIG> (but not enumerated) is understood to be those shown in <FIG>.

In <FIG>, the nut-retaining function is accomplished via the predetermined placement of two retainers 69d' and 69d". As shown, a first end of retainer 69d' engages recess 65d' of integral cradle wall 63d, and a second end of retainer 69d' engages recess 66d' of integral cradle wall 64d. In addition, as shown in <FIG>, a first end of retainer 69d" engages recess 65d" of integral cradle wall 63d, and a second end of retainer 69d" engages recess 66d" of integral cradle wall 64d. As shown in <FIG>, the recesses 65d', 65d" and 66d', 66d" are configured and additively manufactured to a dimension and/or geometry that more closely matches or otherwise more closely approximates the dimension and/or geometry of first and second ends of retainers 69d' and 69d". The remainder of the features shown in <FIG> (but not enumerated) is understood to be those shown in <FIG>.

In <FIG>, the nut-retaining function is accomplished via the predetermined placement of two retainers 69e' and 69e". As shown, a first end of retainer 69e' engages through-slot 65e' of integral cradle wall 63e, and a second end of retainer 69e' engages through-slot 66e' of integral cradle wall 64e. In addition, as shown in <FIG>, a first end of retainer 69e" engages through-slot 65e" of integral cradle wall 63e, and a second end of retainer 69e" engages through-slot 66e" of integral cradle wall 64e. As shown in <FIG>, the through-slots 65e', 65e" and 66e', 66e" are configured and additively manufactured to a dimension and/or geometry that closely matches or otherwise closely approximates the dimension and/or geometry of first and second ends of retainers 69e' and 69e". The remainder of the features shown in <FIG> (but not enumerated) is understood to be those shown in <FIG>.

In <FIG>, the nut-retaining function is accomplished via the predetermined placement of two retainers 69f' and 69f'. As shown, a first end of retainer 69f' engages through-slot 65f' of integral cradle wall 63f, and a second end of retainer 69f' e engages through-slot 66f' of integral cradle wall 64f. In addition, as shown in <FIG>, a first end of retainer 69f" engages through-slot 65f" of integral cradle wall 63f, and a second end of retainer 69f" engages through-slot 66f" of integral cradle wall 64f. As shown in <FIG>, the through-slots 65f', 65f" and 66f', 66f" are configured and additively manufactured to a dimension and/or geometry that closely matches or otherwise closely approximates the dimension and/or geometry of first and second ends of retainers 69f' and 69f". In addition, as shown in <FIG>, the first and second ends of retainers 69f' and 69f" are shown extending past the outer wall of the cradle walls 63f and 64f via through slots 65f', 65f" and 66f', 66f" respectively. This aspect of retainer elements extending past the outer walls of the integral and additively manufactured cradle walls is understood as pertaining to any retainer used in conjunction with aspects of the present disclosure. The remainder of the features shown in <FIG> (but not enumerated) is understood to be those shown in <FIG>.

<FIG> is a flowchart outlining an aspect of the present disclosure directed to a method <NUM> for attaching a first component to a second component comprising positioning <NUM> an additively manufactured first component proximate to a second component, said first component comprising a nut plate, said nut plate comprising an additively manufactured nut-retaining cradle, with the additively manufactured nut-retaining cradle dimensioned to receive the nut and a nut retainer and, attaching <NUM> the additively manufactured first component to the second component.

<FIG> is a flowchart outlining an aspect of the present disclosure directed to a method <NUM> for attaching a first component to a second component comprising positioning <NUM> an additively manufactured first component proximate to a second component, said first component comprising a nut plate, said nut plate comprising an additively manufactured nut-retaining cradle, with the additively manufactured nut-retaining cradle dimensioned to receive the nut and a nut retainer, engaging <NUM> the nut plate of the first additively manufactured component and the second component with a fastener, fastening <NUM> the second component to the nut plate of the first additively manufactured component, and joining <NUM> the additively manufactured first component to the second component. According to a further aspect, the second component is also an additively manufactured component, and in yet another aspect, the nut plate is a rivetless nut plate.

According to the present disclosure, the terms "parts" or "parts" are used equivalently and interchangeably with the respective terms "component" or "components. Further, the term "nut plate" is used equivalently and interchangeably with the respective term "nut plate assembly". Additionally, the terms "recess" or "recesses" are used equivalently and interchangeably with the respective terms "depression", "depressions", "dimple", "dimples".

Further, aspects of the present disclosure contemplate the use of additively manufactured parts comprising the integral additively manufactured nut cradle to manufacture stationary structures comprising the additively manufactured parts. Such stationary structures include, without limitation, buildings, structural supports, bridges, trusses, and any structure comprising component and parts comprising nut plates.

Further aspects of the present disclosure contemplate the use of additively manufactured parts comprising the integral additively manufactured nut cradle to manufacture structural and other components for vehicles including, without limitation, aircraft (e.g. spars, ribs, stringers, etc.). Vehicles further include, without limitation, manned aircraft, an unmanned aircraft, a manned spacecraft, an unmanned spacecraft, a manned rotorcraft, an unmanned rotorcraft, a satellite, a rocket, a missile, a manned terrestrial vehicle, an unmanned terrestrial vehicle, a manned surface water borne vehicle, an unmanned surface water borne vehicle, a manned sub-surface water borne vehicle, an unmanned sub-surface water borne vehicle, and combinations thereof.

Claim 1:
An additively manufactured part comprising:
an additively manufactured nut-retaining cradle integral with the additively manufactured part, said integral nut-retaining cradle comprising an integral cradle bed (<NUM>) (<NUM>) (<NUM>) (62a) and at least one integral cradle wall (<NUM>) (<NUM>) (<NUM>) (<NUM>) (<NUM>) (<NUM>) (63a) (64a) (63b) (64b) ((63c) (64c) (63d) (64d) (63e) (64e) (63f) (64f), said integral cradle wall extending substantially perpendicularly from the integral cradle bed and said integral cradle wall extending from the integral cradle bed to a predetermined distance; and
wherein the integral cradle wall comprises at least one integral cradle wall nut-retaining feature (<NUM>) (<NUM>) (<NUM>) (<NUM>) (<NUM>) (<NUM>) (65a) (66a) (65b) (66b) ((65c) (66c) (65d') (65d") (66d') (66d") (66e') (66e") (66f') (66f"), said integral cradle wall nut-retaining feature configured to receive a retainer (<NUM>) (<NUM>) (<NUM>) (69a) (69c') (69c") (69d') (69d"), (69ee') (69e") (69f') (69f") said retainer configured to engage the integral cradle wall nut-retaining feature, said integral cradle wall nut-retaining feature further configured to establish a restricted range of movement for a nut retained in the nut-retaining cradle along at least one axis,
wherein the integral cradle wall nut-retaining feature comprises at least one recess (65a) (66a) (65b) (66b) (65c) (66c) (65d') (65d") (66d') (66d") in at least one integral cradle wall (<NUM>, <NUM>).