Method of making nut fasteners

• US 10,220,575 B2
• Filed: 11/22/2016
• Issued: 03/05/2019
• Est. Priority Date: 06/02/2011
• Status: Expired due to Fees

• Current Assignee: A Raymond Et Compagnie
• Original Assignee: A Raymond Et Compagnie
• Inventors: Reznar, Jason F.
• Primary Examiner(s): Tentoni, Leo B
• Application Number:
  US15/358,927
• Publication Number:
  US 20170072629A1
• Time in Patent Office: 833 Days
• Field of Search: 2642971, 2642978, 264308, 264401, 264460, 264461, 264462, 264463, 264494, 264496, 264497
• CPC Class Codes: B22F 10/28 Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
• CPC Class Codes: B22F 10/47 characterised by structural features
• CPC Class Codes: B22F 5/06 of threaded articles, e.g. nuts
• CPC Class Codes: B28B 1/001 Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material selective deposition modelling of metallic powder B22F10/00; rapid manufacturing of 3D objects in general and in particular of plastics B29C64/00
• CPC Class Codes: B29C 2035/0827 using UV radiation
• CPC Class Codes: B29C 35/0805 using electromagnetic radiation
• CPC Class Codes: B29C 64/112 using individual droplets, e.g. from jetting heads
• CPC Class Codes: B29C 64/118 using filamentary material being melted, e.g. fused deposition modelling [FDM]
• CPC Class Codes: B29C 64/124 using layers of liquid which are selectively solidified
• CPC Class Codes: B29C 64/129 characterised by the energy source therefor, e.g. by global irradiation combined with a mask
• CPC Class Codes: B29C 64/135 the energy source being concentrated, e.g. scanning lasers or focused light sources
• CPC Class Codes: B29C 64/147 using sheet material, e.g. laminated object manufacturing [LOM] or laminating sheet material precut to local cross sections of the 3D object
• CPC Class Codes: B29C 64/153 using layers of powder being selectively joined, e.g. by selective laser sintering or melting
• CPC Class Codes: B29C 64/171 specially adapted for manufacturing multiple 3D objects
• CPC Class Codes: B29C 64/176 Sequentially
• CPC Class Codes: B29C 64/182 in parallel batches
• CPC Class Codes: B29C 64/393 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B29C 64/40 Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
• CPC Class Codes: B29K 2105/0002 monomers or prepolymers
• CPC Class Codes: B29L 2001/005 Nuts
• CPC Class Codes: B29L 2031/727 : Fastening elements bolts B29L2001/002; nuts B29L2001/005; screws B29L2001/007; slide fasteners B29L2005/00; buttons for haberdashery B29L2019/00
• CPC Class Codes: B33Y 10/00 : Processes of additive manufacturing
• CPC Class Codes: B33Y 50/02 : for controlling or regulating additive manufacturing processes
• CPC Class Codes: B33Y 70/00 : Materials specially adapted for additive manufacturing
• CPC Class Codes: B33Y 80/00 : Products made by additive manufacturing
• CPC Class Codes: F16B 19/002 : Resiliently deformable pins F16B21/06 takes precedence
• CPC Class Codes: F16B 19/1081 : fastened by a drive-pin F16B19/109 takes precedence
• CPC Class Codes: F16B 2200/75 : Fasteners made by sintering powders
• CPC Class Codes: F16B 29/00 : Screwed connection with deformation of nut or auxiliary member while fastening Nuts fastened to surfaces by riveting F16B37/065; members deformed for locking screws, bolts or nuts F16B39/22
• CPC Class Codes: F16B 33/006 : Non-metallic fasteners using screw-thread
• CPC Class Codes: F16B 37/00 : Nuts or like thread-engaging members specially shaped for rotations by a tool F16B23/00
• CPC Class Codes: F16B 37/041 : Releasable devices F16B37/044, F16B37/045 take precedence
• CPC Class Codes: F16B 37/0842 : fastened to the threaded bolt with snap-on-action, e.g. push-on nuts for stud bolts F16B37/0857 takes precedence; snap-on-action of a pin, spigot, shaft or the like and a member surrounding it F16B21/06
• CPC Class Codes: F16B 39/30 : Locking exclusively by special shape of the screw-thread
• CPC Class Codes: F16B 5/0233 : allowing for adjustment perpendicular to the plane of the plates
• CPC Class Codes: F16B 5/0635 : fastened over the edges of the sheets or plates
• CPC Class Codes: F16B 5/0642 : the plates being arranged one on top of the other and in full close contact with each other
• CPC Class Codes: F16B 5/065 : the plates being one on top of the other and distanced from each other, e.g. by using protrusions to keep contact and distance
• CPC Class Codes: F16B 7/0493 : forming a crossed-over connection
• CPC Class Codes: H02G 3/32 : using mounting clamps
• CPC Class Codes: Y02P 10/25 : Process efficiency

Abstract

A fastener is provided. In another aspect, a fastener is 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.

Claims

1. A method of making a fastener, the method comprising:

(a) creating a first layer of material to define a first section of the fastener;

(b) emitting light onto the first layer after the prior step to cure, harden or bond the layer;

(c) creating a second layer of the material upon the first layer to define a second section of the fastener after the prior step;

(d) emitting light onto the second layer after the prior step to cure, harden or bond the second layer;

(e) creating at least a third layer of the material upon the second layer to define at least a third section of the fastener after the prior step;

(f) emitting light onto the third layer after the prior step to cure, harden or bond the third layer;

(g) making flexible side walls from at least some of the creating steps that are moveable away from each other if an elongated shaft is inserted therebetween, and making a base wall with an internal bore from at least some of the creating steps, the side walls extending from the base wall;

(h) removing the finished fastener from a machine which performs the creating and emitting steps, with the layers all being integrally connected to their adjacent layers; and

(i) the finished fastener being functional and made by the machine in less than ninety minutes.

2. The method of claim 1, further comprising depositing the first layer of the material from a printing head onto a support surface of the machine in an ambient and unpressurized air environment.

3. The method of claim 1, wherein the material is a light curable polymer.

4. The method of claim 1, wherein the light is ultraviolet light which is immediately passed over each layer of the fastener after it is deposited.

5. The method of claim 1, further comprising making a workpiece-securing leg and a laterally enlarged flange, as part of at least some of the creating steps in the machine.

6. The method of claim 1, further comprising making a flexible section of the fastener by creating another layer of a different material, the first section being of a more rigid material than the flexible section.

7. The method of claim 1, further comprising creating the fastener in an additive manner as a box nut with workpiece-engaging legs.

8. The method of claim 1, further comprising:

attaching a threaded component, which is the shaft, with the bore which is threaded;

insertion of the threaded shaft outwardly flexing the side walls about pivot axes adjacent outboard corners of the base wall; and

the threaded shaft being adapted for disassembly from the base wall after manufacturing.

9. The method of claim 1, further comprising depositing a second and different material integrally connected to the first material during the same machine head pass above the fastener being created, the second material being more resilient than the first material which is used for the base wall, to create an anti-rattling layer.

24. The method of claim 1, further comprising additively making an outwardly projecting workpiece-engaging leg extending from each of the side walls.

25. The method of claim 1, further comprising additively making the side walls and base wall to define a substantially rectangular shape.

26. The method of claim 1, further comprising additively making the side walls and base wall to define a substantially triangular shape.

10. A method of making a fastener, the method comprising:

(a) depositing a layer of a first material within a machine, the layer defining an outer surface of the fastener;

(b) depositing subsequent layers of a second material upon each prior layer until the fastener is completely created, the first material being of a resilient and anti-rattling polymer, and the second material being more rigid than the first material;

(c) creating the fastener to comprise an internally threaded nut made of the second material, as part of the depositing steps;

(d) surrounding at least a majority of the fastener with a gas during the depositing and creating steps;

(e) curing the fastener so that the layers of the material layers bond together; and

(f) removing the completed anti-rattle covered nut fastener from the machine.

11. The method of claim 10, wherein the nut includes at least two moveable workpiece-engaging legs connected by a body, further comprising creating an internally threaded hole in the body, and attaching an elongated member in the hole so that the elongated member spreads apart the legs when fully installed in a workpiece-fastening condition.

12. The method of claim 10, wherein the gas is air, and the fastener is a single piece.

13. The method of claim 10, further comprising flowing the first material and the second material from a machine head positioned above the support surface, at least one of the machine head and the support surface automatically moving relative to the other according to computer instructions in order to create identical multiples of the fastener in the same machine cycle, free of contraction or expansion due to the manufacture thereof.

14. The method of claim 10, wherein at least one of the materials is a three-dimensionally printable polymer.

15. The method of claim 10, wherein at least one of the materials is a polymeric string emitted from a moveable machine head in a continuous manner from a spool which supplies the string to the head.

16. The method of claim 10, wherein the second material is metal.

17. The method of claim 10, wherein at least ten of the fasteners are substantially simultaneously manufactured in a single machine cycle in less than ninety minutes.

18. The method of claim 10, further comprising flowing at least one of the materials from an ink jet printing head including openings arranged in an array such that multiple material flows are simultaneously occurring for each layer of the fastener.

19. The method of claim 10, further comprising making workpiece-securing legs and a laterally enlarged flange by additively layering and light curing.

20. The method of claim 10, wherein the nut is three dimensionally printed to include a base wall with a threaded hole and a pair of flexible side walls projecting from the base wall, each of the side walls including a workpiece-engaging leg.

21. The method of claim 20, wherein the base and side walls define a substantially triangular shape with a hollow internal space between the walls in an unfastened condition.

22. The method of claim 20, wherein the base and side walls define a substantially rectangular shape with a hollow internal space between the walls in an unfastened condition.

23. The method of claim 10, wherein the nut is a cage nut.

27. A method of making a fastener, the method comprising three dimensionally printing a nut including a base wall and upstanding side walls adapted to flex relative to the base wall, with the base wall including a hole adapted to receive a threaded shaft therein, and workpiece-engaging surfaces being created to outwardly project from the side walls.

28. The method of claim 27, further comprising three dimensionally printing an anti-vibrational layer adjacent at least one of the walls.

29. The method of claim 28, wherein the anti-vibrational layer acts as a workpiece-to-nut seal.

30. The method of claim 27, wherein the workpiece-engaging surfaces are legs outwardly projecting from a middle portion of the side walls which are unpierced adjacent the legs.

31. The method of claim 30, further comprising:

additively printing a flange outwardly projecting from each of the side walls adjacent to the base wall;

an outer end of each of the legs diagonally pointing toward the flange; and

each set of the legs and flanges being adapted to receive a workpiece sheet therebetween with the side walls being received in a hole of the workpiece sheet.

32. The method of claim 27, wherein the nut is printed from an additively layered polymer.

33. The method of claim 27, wherein the nut is printed from an additively layered metal.

34. The method of claim 27, wherein the nut is a substantially rectangular box nut with a hollow internal center between the side walls.

35. The method of claim 27, wherein the walls define a substantially triangular shape with a hollow internal center between the side walls.