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

1. A leadscrew assembly comprising:

a leadscrew comprising a leadscrew thread wire helically wound about a leadscrew axis in a plurality of cylindrical leadscrew-thread turns and having a leadscrew-thread pitch; and

a leadscrew wire nut assembly comprising

a nut-assembly wire helically wound about the leadscrew axis in a plurality of cylindrical nut-assembly turns and having a nut-assembly-thread pitch, wherein the nut-assembly-thread pitch is substantially the same as the leadscrew-thread pitch, wherein the nut-assembly turns overlie and mesh with the leadscrew-thread turns, and wherein the nut-assembly wire has a permanent deformation therein,

a wire-nut-assembly housing overlying and bonded to at least some of the nut-assembly turns, and

a mechanical drive in rotational communication with the leadscrew.

2. The leadscrew assembly of claim 1 , wherein the leadscrew wire nut assembly comprises

the nut-assembly wire having a first axial wire region, a second axial wire region, and a third axial wire region lying between the first axial wire region and the second axial wire region,

a first wire nut region comprising at least one turn of the first axial wire region overlying and engaged to a groove between the leadscrew-thread turns,

a second wire nut region comprising at least one turn of the second axial wire region overlying and engaged to the groove between the leadscrew-thread turns, wherein the second wire nut region is spaced apart from the first wire nut region along the leadscrew axis, and wherein the third axial wire region maintains a compression preload against the first wire nut region and the second wire nut region.

3. The leadscrew assembly of claim 2 , wherein the third axial wire region has a circumferentially extending volume of material removed therefrom.

4. The leadscrew assembly of claim 1 , wherein the first wire nut region and the second wire nut region are bonded to the wire-nut-assembly housing, and wherein at least the second wire nut region is resiliently bonded to the wire-nut-assembly housing.

5. The leadscrew assembly of claim 1 , wherein the nut-assembly wire has a first cross-sectional wire area in the first axial wire region, a second cross-sectional wire area in the second axial wire region, and a third cross-sectional wire area in the third axial wire region, and wherein the third cross-sectional wire area is less than either of the first cross-sectional wire area and the second cross-sectional wire area.

6. The leadscrew assembly of claim 1 , wherein the nut-assembly wire is wound into a nut-assembly wire coil having a substantially constant inner diameter and a first-axial-wire-region outer diameter, a second-axial-wire-region outer diameter, and a third-axial-wire-region outer diameter, and wherein the third-axial-wire-region outer diameter is less than either of the first-axial-wire-region outer diameter and the second-axial-wire-region outer diameter.

7. The leadscrew assembly of claim 1 , wherein the leadscrew has no shaft extending therethrough.

8. The leadscrew assembly of claim 1 , wherein the leadscrew thread wire is helically wrapped in spaced-apart turns.

9. The leadscrew assembly of claim 1 , wherein the leadscrew thread wire is helically wrapped in contacting turns.

10. The leadscrew assembly of claim 1 , wherein the leadscrew assembly further includes

a motor that rotationally drives the leadscrew.

11. The leadscrew assembly of claim 1 , wherein the wire-nut assembly housing is a single continuous piece of a wire-nut-assembly housing material.

12. The leadscrew assembly of claim 1 , wherein the nut-assembly wire is a single continuous piece of wire material.

13. 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 single length of nut-assembly wire wound in cylindrical wire-helix turns about the leadscrew axis with an inner diameter of the cylindrical-wire turns of the nut-assembly wire greater than an outer diameter of the cylindrical-helix turns of the thread wire, and wherein the nut-assembly wire has a first axial wire region, a second axial wire region, and a third axial wire region lying between the first axial wire region and the second axial wire region,

a first wire nut region comprising at least one turn of the first axial wire region overlying and engaged to the groove between the turns of the thread wire,

a second wire nut region comprising at least one turn of the second axial wire region overlying and engaged to the groove between the turns of the thread wire,

wherein the second wire nut region is spaced apart from the first wire nut region along the leadscrew axis,

wherein the nut assembly wire has a first cross-sectional wire area in the first axial wire region, a second cross-sectional wire area in the second axial wire region, and a third cross-sectional wire area in the third axial wire region, and wherein the third cross-sectional wire area is less than either of the first cross-sectional wire area and the second cross-sectional wire area, and

wherein the third axial wire region maintains a compression preload against the first wire nut region and the second wire nut region, and

a wire-nut-assembly housing overlying the first axial wire region, the second axial wire region, and the third axial wire region, wherein the first wire nut region and the second wire nut region are bonded to the wire-nut-assembly housing, and wherein at least one of the first wire nut region and the second wire nut region is compliantly bonded to the wire-nut-assembly housing.

14. The leadscrew assembly of claim 13 , wherein the leadscrew assembly further includes

a motor that rotationally drives the leadscrew.