Channel Nut with Offset Notches

Abstract

A channel nut includes a web, a first flange projecting from the web where the first flange has a first notch for receiving a first lip of a strut channel, and a second flange projecting from the web where the second flange has a first notch for receiving the first lip of the strut channel. The first notch of the first flange and the first notch of the second flange are arranged in a non-aligned relationship with respect to each other such that the first notch of the first flange and the first notch of the second flange form a curved first seat for the first lip of the strut channel.

Claims

1.-16. (canceled)

17. A channel nut, comprising: a web (3); a first flange (1) projecting from the web (3), wherein the first flange (1) has a first notch (11) for receiving a first lip (81) of a strut channel; and a second flange (2) projecting from the web (3), wherein the second flange (2) has a first notch (21) for receiving the first lip (81) of the strut channel; wherein the first notch (11) of the first flange (1) and the first notch (21) of the second flange (2) are arranged in a non-aligned relationship with respect to each other such that the first notch (11) of the first flange (1) and the first notch (21) of the second flange (2) form a curved first seat (61) for the first lip (81) of the strut channel.

18. The channel nut according to claim 17, wherein the channel nut is a sheet metal part.

19. The channel nut according to claim 17, wherein the first notch (11) of the first flange (1) is V-shaped and/or the first notch (21) of the second flange (2) is V-shaped.

20. The channel nut according to claim 19, wherein the V-shaped first notch (11) of the first flange (1) has a rounded bottom and/or the V-shaped first notch (21) of the second flange (2) has a rounded bottom.

21. The channel nut according to claim 17, wherein the first flange (1) and the second flange (2) are parallel to each other, wherein the first flange (1) is perpendicular to the web (3), and wherein the second flange (2) is perpendicular to the web (3).

22. The channel nut according to claim 21, wherein the first notch (11) of the first flange (1) and the first notch (21) of the second flange (2) are offset with respect to one another in a reference direction (95) that extends parallel to a mold line (94) formed between the web (3) and the first flange (1).

23. The channel nut according to claim 17, wherein the first notch (11) of the first flange (1) extends perpendicularly with respect to at least one of two flange faces (63, 63) of the first flange (1) through the first flange (1) and/or wherein the first notch (21) of the second flange (2) extends perpendicularly with respect to at least one of two flange faces (64, 64) of the second flange (2) through the second flange (2).

24. The channel nut according to claim 17, wherein the first notch (11) of the first flange (1) extends entirely through the first flange (1) and/or wherein the first notch (21) of the second flange (2) extends entirely through the second flange (2).

25. The channel nut according to claim 17, wherein the web (3) has a mounting through hole (8) for receiving a mounting bolt.

26. The channel nut according to claim 17, wherein the first flange (1) has a second notch (12) for receiving a second lip (82) of the strut channel, wherein the second flange (2) has a second notch (22) for receiving the second lip (82) of the strut channel, and wherein the second notch (12) of the first flange (1) and the second notch (22) of the second flange (2) are arranged in a non-aligned relationship with respect to each other such that the second notch (12) of the first flange (1) and the second notch (22) of the second flange (2) form a curved second seat (62) for the second lip (82) of the strut channel.

27. The channel nut according to claim 26, wherein the first notch (11) of the first flange (1), the second notch (22) of the second flange (2), the second notch (12) of the first flange (1), and the first notch (21) of the second flange (2) form a 180 rotationally symmetric pattern.

28. A fastener arrangement, comprising: the channel nut according to claim 17; and a strut channel that includes a first lip (81), wherein the first lip (81) of the strut channel is disposed in the curved first seat (61) of the channel nut.

29. The fastener arrangement according to claim 28, wherein the first lip (81) is untoothed.

30. A method for manufacturing the channel nut according to claim 17, comprising: a cutting step in which at least the first notch (11) of the first flange (1) is cut; and a notch resizing step which follows the cutting step in which at least the first notch (11) of the first flange (1) is resized by laterally pressing at least one calibration tool (91) against a notch surface (51) of the first notch (11) of the first flange (1) thereby work hardening material adjacent to the notch surface (51) of the first notch (11) of the first flange (1).

31. The method according to claim 30, wherein: in the cutting step, at least the first notch (11) of the first flange (1) and the first notch (21) of the second flange (2) are cut; the calibration tool (91) is a common calibration tool (91); and in the notch resizing step, at least the first notch (11) of the first flange (1) and the first notch (21) of the second flange (2) are resized by laterally pressing the at least one common calibration tool (91) against the notch surface (51) of the first notch (11) of the first flange (1) and, simultaneously, against a notch surface (52) of the first notch (21) of the second flange (2) thereby work hardening respective flange material adjacent to the notch surface (51) of the first notch (11) of the first flange (1) and adjacent to the notch surface (52) of the first notch (21) of the second flange (2).

32. The method according to claim 30, further comprising a flange bending step in which at least the first flange (1) is bent up, wherein the flange bending step follows the cutting step and wherein the notch resizing step follows the flange bending step.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0035] FIGS. 1 to 8 are different views of an example of a channel nut.

[0036] FIGS. 9 to 11 are different views of a fastener arrangement comprising the channel nut of FIGS. 1 to 8 and a strut channel.

[0037] FIGS. 12 to 14 shown consecutive stages of a method for manufacturing the channel nut of FIGS. 1 to 8.

DETAILED DESCRIPTION OF THE DRAWINGS

[0038] FIGS. 1 to 8 show an example of a channel nut. The shown channel nut comprises a flat web 3, which has essentially angled-parallelogram shaped outline. A mounting through hole 8 traverses the web 3. The mounting through hole 8 extends perpendicular to the web 3, i.e., perpendicular to the faces of the web 3, which faces are penetrated by the mounting through hole 8. The axis of the mounting through hole 8, which is orientated perpendicular to the faces of the web 3, is coaxial with the centre of the parallelogram shape. The mounting through hole 8 is threaded. The channel nut moreover comprises a collar 9, which projects from the web 3, and which is arranged coaxially with respect to the mounting through hole 8. The collar 9 extends the thread length of the mounting through hole 8 and stiffens the web 3.

[0039] The channel nut further comprises a first flange 1 and a second flange 2. The first flange 1 and the second flange 2, respectively, project from opposite edges of the parallelogram-shaped web 3, into the same direction. Both the first flange 1 and the second flange 2 have essentially rectangular outline. The first flange 1 and the second flange 2 are parallel to each other. The web 3, the first flange 1 and the second flange 2 form a structure having a U-shaped cross-section, wherein flanges 1 and 2 define the side legs and the web 3 the middle leg of the U-shape. The above-mentioned collar 9 projects in the same direction as the flanges 1 and 2 do, i.e., the collar 9 is arranged between the flanges 1 and 2.

[0040] The first flange 1 has two parallel flange faces 63 and 63, and an edge surface 65 connecting the flange faces 63 and 63. Flange face 63 of the first flange 1 faces the second flange 2. The second flange 2 has two parallel flange faces 64 and 64, and an edge surface 66 connecting the flange faces 64 and 64. Flange face 64 of the second flange 2 faces the first flange 1.

[0041] The channel nut is a sheet metal part and thus, the first flange 1, the second flange 2 and the web 3 are integral. Preferably, these flanges 1 and 2 and the web 3 consist of steel and or have same thickness.

[0042] The first flange 1 is provided with a first notch 11 and with a second notch 12. Each of these notches 11, 12 originates from the edge surface 65 of the first flange 1, more precisely from a section of the edge surface 65 which is arranged remote from the web 3, opposite the web 3, on the first flange 1. Originating from the edge surface 65 of the first flange 1, the notches 11 and 12 of the first flange 1 point towards the web 3. Each of the notches 11 and 12 of the first flange 1 is V-shaped, with a rounded bottom. In cross direction, the notches 11, 12 extend all the way through the first flange 1, i.e., they extend from the inner flange face 63 of the first flange 1 to the outer flange face 63 of the first flange 1. The first notch 11 of the first flange 1 is, at least regionally, limited by an essentially cylindrical notch surface 51 (a generalised cylinder is the surface formed by the motion of a linethe generatormoving parallel to itself and intersecting a given curvethe directrixwhich directrix would be an open curve in the present case). The notch surface 51 and/or the axis of the first notch 11 of the first flange 1 extend perpendicularly to both flange faces 63 and 63 of the first flange 1, i.e., the first notch 11 is a perpendicular hole with respect to both flange faces 63 and 63 of the first flange 1. In analogy, the second notch 12 of the first flange 1 is a perpendicular hole with respect to both flange faces 63 and 63 of the first flange 1.

[0043] The second flange 2 is provided with a first notch 21 and with a second notch 22. Each of these notches 21, 22 originates from the edge surface 66 of the second flange 2, more precisely from a section of the edge surface 66 which is arranged remote from the web 3, opposite the web 3, on the second flange 2. Originating from the edge surface 66 of the second flange 2, the notches 21 and 22 of the second flange 2 point towards the web 3. Each of the notches 21 and 22 of the second flange 2 is V-shaped, with a rounded bottom. In cross direction, the notches 21, 22 extend all the way through the second flange 2, i.e., they extend from the inner flange face 64 of the second flange 2 to the outer flange face 64 of the second flange 2. The first notch 21 of the second flange 2 is, at least regionally, limited by an essentially cylindrical notch surface 52. The notch surface 52 and/or the axis of the first notch 21 of the second flange 2 extend perpendicularly to both flange faces 64 and 64 of the second flange 2, i.e., the first notch 21 is a perpendicular hole with respect to both flange faces 64 and 64 of the second flange 2. In analogy, the second notch 22 of the second flange 2 is a perpendicular hole with respect to both flange faces 64 and 64 of the second flange 2.

[0044] The first notch 11 of the first flange 1 and the first notch 21 of the second flange 2 are arranged with an offset 96 (explicitly indicated in FIG. 7) in a reference direction 95, which reference direction 95 extends parallel to the outer mold line 94 formed between the web 3 and the first flange 1. Accordingly, the reference direction 95 is both parallel to the flange faces 63 and 63 of the first flange 1 and parallel to the faces of the web 3. In the shown embodiment, the outer mold line 94 formed between the web 3 and the first flange 1 is parallel to the outer mold line formed between the web 3 and the second flange 2, since the flanges 1 and 2 are parallel. Therefore, the reference direction 95 extends also parallel to the outer mold line formed between the web 3 and the second flange 2 and the reference direction 95 is both parallel to the flange faces 64 and 64 of the second flange 2 and parallel to the faces of the web 3.

[0045] The second notches 12 and 22 also have offset in the reference direction 95, and the offset of the second notches 12 and 22 is the same as that of the first notches 11 and 21. All of the notches 11, 22, 12 and 22 have essentially the same shape. The notches 11, 22, 12 and 22 form a pattern that is 180 rotationally symmetric around an axis that is coaxial with the axis of the mounting through hole 8. Each of the notches 11, 22, 12 and 22 has a respective notch wall, which delimits the respective notch.

[0046] Due to their offset 96 and due to their perpendicular alignment with respect to the flanges 1 and 2, the first notches 11 and 21, in particular their respective notch walls, are in an axially non-aligned relationship with respect to each other. They thus form a curved first seat 61 (explicitly indicated in FIG. 8) for a straight first lip 81 of a strut channel. In analogy, due to their offset and due to their perpendicular alignment with respect to the flanges 1 and 2, also the second notches 12 and 22, in particular their respective notch walls, are in an axially non-aligned relationship with respect to each other. They thus form a curved second seat 62 (explicitly indicated in FIG. 8) for a straight second lip 82 of a strut channel.

[0047] The channel nut can be fixed to a strut channel, resembling that which is shown in FIGS. 9 to 11. The shown strut channel is a C-channel and comprises a channel bottom 87 and two parallel channel walls 85 and 86 projecting therefrom. The first lip 81 of the strut channel inwardly projects from the first channel wall 85 and the second lip 82 of the strut channel inwardly projects from the second channel wall 86.

[0048] During installation, the channel nut is so positioned that the first lip 81 of the strut channel is received in the curved first seat 61 of the channel nut and the second lip 82 of the strut channel is received in the curved second seat 62 of the channel nut. Pre-fixing in this position can be effected by anot-shownspring connected to the channel nut and resting either on the channel bottom 87 or on the lips 81, 82 of the strut channel, as generally known in the art. The lips 81 and 82 are then pressed into their respective curved seats 61 or 62, for example by means of a not shown bolt screwingly engaging the mounting through hole 8. As the curved seats 61 and 62 intentionally mismatch the corresponding straight lips 81 and 82, forcing the lips 81 and 82 into their respective seats 61 or 62 causes stress and deformation. In particular, the flanges 1 and 2 may cut into the lips 81 and 82 and/or the lips 81 and 82 may bend into their respective curved seats 61 or 62. This can create a robust interlock between the channel nut and the strut channel, preferably an interlock that can also withstand significant shear forces directed alongside the strut channel. In particular, the first flange 1 may cut into the first lip 81 at the first notch 11 of the first flange 1 and the second flange 2 may cut into the first lip 81 at the first notch 21 of the second flange 2 and/or the first flange 1 may cut into the second lip 82 at the second notch 12 of the first flange 1 and the second flange 2 may cut into the second lip 82 at the second notch 21 of the second flange 2.

[0049] In particular, due to the intentional misalignment, two opposite ridges arise on each of the first notches 11, 12, which ridges can laterally engage the straight first lips 81 of the strut channel when the first lip 81 is positioned within the seat 61 created by the first notches 81, 82. The ridges, acting against the first lip 81 on both sides, can focus the stress on a line, which can aid the penetration into the lip 81 of the strut channel from both sides. An analogous configuration is present at the second notches 21, 22 and the second lip 82.

[0050] FIGS. 12 to 14 illustrate consecutive steps of a method for manufacturing the described channel nut. In a first cutting step, all of the first notches 11, 21 and second notches 12, 22 are cut out of a mostly (in particular except for the collar 9) flat metal workpiece using sheet metal stamping. The structure resulting from this step is shown in FIG. 12.

[0051] Afterwards, in a flange bending step, the first flange 1 and the second flange 2 are bent up from the web 3, resulting in the structure shown in FIG. 13.

[0052] Afterwards, in a notch resizing step, a calibration tool 91 is laterally, with respect to the first flange 1 and with respect to the second flange 2, pressed into each of the notches 11, 12, 21, 22, against their respective notch surfaces 51, 52, thereby slightly enlarging the notches 11, 12, 21, 22 and work hardening the surrounding channel nut material. This process is illustrated in FIG. 14, in which the direction of operation of the calibration tool 91 is indicated by arrows. In the shown embodiment, the calibration tool 91 is a common calibration tool which simultaneously acts in all of the notches 11, 12, 21, 22. However, it is also possible to use separate calibration tools for one or more of the notches 11, 12, 21, 22.