Wire-wound leadscrew assembly with a preloaded leadscrew wire nut, and its fabrication

A leadscrew assembly comprising:

• a leadscrew comprising a thread wire helically wrapped in a plurality of cylindrical-helix turns about a leadscrew axis and having a groove between the turns, wherein the leadscrew has no shaft extending therethrough;
• a mechanical drive in rotational communication with the leadscrew;
• and
• a leadscrew wire nut assembly comprising
• a first wire nut comprising at least one turn of a first-nut wire overlying and engaged to the groove between the turns of the thread wire, wherein the first-nut wire is of substantially the same diameter as the thread wire,
• a second wire nut comprising at least one turn of a second-nut wire overlying and engaged to the groove between the turns of the thread wire, wherein the second-nut wire is of substantially the same diameter as the thread wire, and wherein the second wire nut is spaced apart from the first wire nut along the leadscrew axis,
• a compressed preload spring maintaining a compression preload against the second wire nut, and
• a wire-nut-assembly housing overlying the first wire nut, the second wire nut, and the preload spring, wherein the first wire nut and the second wire nut are bonded to the wire-nut-assembly housing, and wherein at least the second wire nut is compliantly bonded to the wire-nut-assembly housing, whereby the wire-nut-assembly housing maintains the preload spring in compression.

A method for fabricating a leadscrew assembly, comprising the steps of

• preparing a leadscrew by wrapping a plurality of turns of a thread wire helically about a leadscrew axis and having a groove between the turns;
• and
• engaging a leadscrew wire nut assembly to the leadscrew, the leadscrew wire nut assembly including,
• a first wire nut comprising at least one turn of a first-nut wire overlying and engaged to the groove between the turns of the thread wire,
• a second wire nut comprising at least one turn of a second-nut wire overlying and engaged to the groove between the turns of the thread wire, wherein the second wire nut is spaced apart from the first wire nut along the leadscrew axis,
• a compressed preload spring maintaining a compression preload against the second wire nut, and
• a wire-nut-assembly housing overlying the first wire nut, the second wire nut, and the preload spring, wherein the second wire nut is compliantly bonded to the wire-nut-assembly housing, and whereby the wire-nut-assembly housing maintains the preload spring in compression.