Abstract:
A fastener assembly comprising a fastener with a head having a first surface and second surface, and a shaft extending from the second surface of the head. An annular washer is rotatably disposed about the shaft and rotatable relative to the second surface of the fastener head. The washer has an inner diameter, an outer diameter, a first surface and a second, the first surface being positioned adjacent to the second surface of the head. A plurality of identical conical projections extend out from the second surface of the washer and are formed integrally therewith.

Description:
RELATED APPLICATION 
     This application is related to and claims priority from U.S. Provisional Application No. 61/198,540, filed on Nov. 6, 2008, which is incorporated herein by reference in its entirety. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to an attachment or fastening system for use in securing two or more structures and, more particularly, to a fastening system for providing electrical conductivity through the secured structures after attachment. 
     BACKGROUND 
     There are a number of fasteners on the market for securing multiple structures together. In certain structural connections, however, it is important to provide an electrical connection or bond between the structures. This is particularly important in situations were a grounded condition is needed. 
     For example, in equipment enclosure racks, such as audio or computer equipment racks, grounding through multiple racks is generally required. Since many racks have a protective paint coating, the direct attachment using conventional nuts and bolts is not, in some cases, sufficient to provide an electrical connection. As such, in order to provide adequate grounding, separate grounding wires are typically used to provide electrical continuity. One end of the grounding wire is attached to a stud or post and the other end is attached to a grounding bus bar mounted to the rack. While this type of attachment is adequate for providing electrical grounding, the attachment of the grounding wires is time consuming and subject to error should the ground connection not be properly completed. 
     A product that was recently introduced by Panduit Corporation is referred to as the Tapped Rail Bonding Stud Kit and includes a nut and bolt arrangement with serrations or teeth formed integral to and on the bottom of the nut and bolt. That product is described in detail in U.S. Patent Publication No. 2006/0257229. 
     While the Panduit product does address the problem for breaking through the paint layer to reach the base metal, Applicant has determined that the product negatively impacts the appearance of the components and can create a corrosion source since the serrations are designed to remove a complete circular ring of paint exposing the bare metal. The ring of bare metal is susceptible to corrosion unless an anti-oxidant is applied. However, application of anti-oxidants is an additional assembly step and can be difficult to apply. 
     SUMMARY OF THE INVENTION 
     A fastener assembly is disclosed that includes a fastener with a head having a first or top surface for engagement by an attachment tool, and second or bottom surface opposite the first surface. A shaft extends out from the second surface of the head and is threaded along at least a portion of the shaft. An annular washer is rotatably disposed about the shaft and rotatable relative to the second surface of the fastener head. The washer a planar body with an inner diameter, an outer diameter, a first surface and a second surface opposite the first surface, the first surface of the washer being positioned adjacent to the second surface of the head. A plurality of substantially identical conical projections extend out from the second surface of the washer and are formed integrally therewith. 
     In one embodiment, the fastener is a bolt and the assembly further includes a nut. The nut has a first surface for engagement by an attachment tool, and a substantially flat second surface. The second surface faces the second surface of the head and the second surface of the annular washer. A second annular washer is disposed about the shaft and rotatable relative to the second surface of the nut and the shaft. The second washer has an inner diameter, an outer diameter, a first surface and a second surface opposite the first surface. The first surface of the washer is positioned adjacent to the second surface of the nut. A plurality of substantially identical conical projections extend out from the second surface of the second washer and are formed integrally therewith. 
     The foregoing and other features of the invention and advantages of the present invention will become more apparent in light of the following detailed description of the preferred embodiments, as illustrated in the accompanying figures. As will be realized, the invention is capable of modifications in various respects, all without departing from the invention. Accordingly, the drawings and the description are to be regarded as illustrative in nature, and not as restrictive. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       For the purpose of illustrating the invention there is shown in the drawings various forms which are presently preferred; it being understood, however, that this invention is not limited to the precise arrangements and instrumentalities particularly shown. 
         FIG. 1  is a perspective view of a portion of two adjacent racks being attached together with a bonding fastener assembly according to the present invention. 
         FIG. 2  is an isometric view of a bonding fastener assembly according to one embodiment of the invention. 
         FIG. 3  is an isometric view of the bonding fastener assembly of  FIG. 2  disassembled. 
         FIG. 4  is a side view of the bonding fastener assembly of  FIG. 2 . 
         FIG. 5  is a top view of the spiked washer according to one embodiment of the invention. 
         FIG. 6  is a side view of the spiked washer of  FIG. 5 . 
         FIGS. 7A-7E  illustrate the how the present invention penetrates the paint coating to form an electrical connection. 
         FIG. 8  is a cross-section of a fastener and nut illustrating the retention of the spiked washers in one embodiment.  FIG. 8A  is an enlargement of a portion of the washer. 
         FIGS. 9A-9C  illustrate different shape spikes for the washer of  FIG. 2 . 
     
    
    
     DETAILED DESCRIPTION 
       FIG. 1  illustrates one embodiment of the bonding fastener assembly  10  of the present invention as it is contemplated for use in attaching two rack assemblies. As shown in  FIGS. 1-3 , the bonding fastener assembly  10  includes a fastener  12  with a head  14 , including a top surface  16  and bottom surface  18 , a shaft  20  and a spiked washer  22 . The top surface  16  of the head  14  has a conventional configuration designed to be engaged with a common installation tool. For example, the head may include a recess for receiving a Phillips head screwdriver, or may have a polygonal shape for engagement with a suitable ratchet. The various configurations that the top surface can be formed in are well known to those skilled in the art and, therefore, no further discussion is needed. The bottom surface  18  of the head  14  is preferably flat. The shaft  20  is integral with the head  14  and extends from the second surface. The shaft  20  includes threads on at least a portion of its surface for engagement with a mating nut or for self tapping into a metal component in a conventional manner. 
     The spiked washer  22  is shown in detail in  FIGS. 2-6 . The spiked washer includes a substantially planar annular ring base  24  with a plurality of conical protrusions or spikes  26  projecting out from one face  28  of the washer  22 . The opposite face  30  does not have any protrusions and, instead, provides a relatively smooth surface for the bottom surface  18  of the head to slide along as will be explained in more detail below. The location and number of the spikes  26  may vary, although the location and number should be chosen so as to provide reliable displacement of and penetration into the painted surface during use and to provide sufficient electrical conductivity through the connection. Substantially even spacing of the spikes around the bottom surface will assist in the washer seating properly with the connecting surface (i.e., lying flat on top of the surface being connected.) 
     In the illustrated embodiment, there are approximately six spikes  26  formed on the bottom surface, evenly spaced about a medial circumference  32  of the washer  22  with a median diameter of approximately 0.50 inches for the illustrated washer  22  that has an overall outer diameter of 0.680 inches and an inner diameter of 0.325 inches. The location of the spikes  26  at this position provides more reliability that the loads imposed on the washer during tightening of the fastener will translate substantially directly through the spikes as an axial piercing force into the painted surface, thereby displacing and penetrating the paint locally and embedding the spikes into the underlying metal material. In another embodiment, the spikes are equally spaced about a circumference that is radially inward but close to the outer edges of the washer. In one embodiment, the washer  22  is made from stainless steel with a thickness of approximately 1/16 th  inch. This is sufficiently thick enough to prevent deforming of the washer during attachment. Deformation is not desired since it can cause the spikes to not embed properly and, thus cause the washer to spin as it is tightened. 
     As discussed above, the spikes  26  are preferably formed integral with the washer  22 . In one preferred embodiment, the washers  22  are cast or formed in a die with the spikes  26  from a high strength electrically conductive material, such as steel, powdered metal, or other well known electrically conductive materials. It is also contemplated that the washer could be formed using a stamping or machining process. As should be evident from the above discussion, the washer  22  should be manufactured with a suitable hardness and stiffness to achieve the desired penetration. If the spikes are too hard, they can break. However, if the spikes are too soft they may deform during tightening and fail to penetrate into the base metal. Thus, proper hardening is needed. This can be achieved though a hardening or heat treat process after the spikes are formed. Preferably the washer is manufactured such that the spikes have a Rockwell hardness of between 30 and 80 (on the C scale) with a more preferred Rockwell hardness of approximately 58. In one preferred embodiment, the washer  22  is formed using a die punching process. A blank washer is placed on a die with appropriately shaped cavities in the die that have a contour configured to form the spikes. A punch is pressed down onto the opposite side of the washer forcing a portion of the material of the washer to flow into the cavities, thereby forming the spikes. 
     The spikes  26  preferably have a height H from the flat face  28  of about 0.062 inches and have a width W of about 0.072 inches at the flat surface, tapering preferably uniformly to the tip  34 . Thus, in one embodiment, the cone has an inclusive angle θ of approximately 60 degrees. The shape and size of the spikes may vary, however the spikes must have a sufficiently sharp tip or edge to sever the painted surface. Also, the inclusive angle must be sufficiently small to provide the sharp piercing point, while still providing sufficient strength so as not to break during installation. A preferred angle θ in the present invention is between about 20 degrees and 120 degrees. More preferably, the inclusive angle is between 30 degrees and 80 degrees. Any narrower than 20 degrees could lead to premature breakage of the spike. Any larger than 120 degrees can lead to the spike failing to sufficiently penetrate the painted layer. 
     As shown in  FIG. 4 , when used in conjunction with a bolted fastener assembly (i.e., with a bolt  12  and nut  36 ) two spiked washers  22  are preferably used, one on either side of the installation with the spikes  26  facing one another. The assembly, when tightened, will break through the painted surfaces from both sides, thus providing electrical continuity. It is also contemplated that the fastener may be a screw or other fastener, instead of the illustrated bolt. 
     In one preferred embodiment of the invention, it is contemplated that the washer  22  is attached to at least the bolt  12 , yet free to rotate about the shaft. For example, a retention clip may be attached to the washer  22  or the shaft  20  and designed to retain the washer on the shaft so that it cannot readily slip off. The attachment would, however, permit the washer to rotate relative to the head so that when the head is tightened, the washer does not rotate. More preferably, as shown in  FIG. 8 , the shaft or shank  20  of the bolt preferably includes a non-threaded portion adjacent to the head  14 . The washer  22  is free to rotate about the non-threaded portion. The washer  22  may be retained on the non-threaded portion simply by threading the washer onto the shaft until it reaches the non-threaded portion. More preferably, the spiked washer is placed on the non-threaded portion prior to threading of the shaft  20 . Threads are then formed on the shaft  22  in a conventional manner. The formation of the threads results in the threads having an outer diameter that is greater than the diameter of the non-threaded portion and the inner diameter of the washer  22 . As such, the washer  22  is retained on the bolt. In one embodiment, the non-threaded portion of the shaft has a length of approximately 5/32 nd  inch and the washer  22  has a thickness of approximately 1/16 th  inch, thus resulting in the washer having approximately 3/32 nd  inch gap to float along the shaft  20 . 
     As also shown in  FIG. 8 , a second washer  22  is also preferably retained on the nut  36 . In one embodiment, this is achieved by forming the nut with an annular extension with a diameter that is less than the inner diameter of the washer. The washer  22  is placed on the extension and the extension is then swaged outward to form a retention lip. The retention lip retains the washer onto the nut while permitting the washer to rotate relative to the nut. In one embodiment, in order to prevent the lip from interfering with the spikes, the washer on the nut is formed with a recessed inner ring with a thickness of approximately 1/32 nd  inch and a diameter of approximately 7/16 th  inch. The annular extension is swaged into a lip that preferably sits within the recessed area. The lip is preferably raised slightly off of the recessed area so that the washer can be rotated relative to the nut while still retained by the lip from separating. 
     One of the unique and unexpected aspects of the invention shown in  FIG. 8  is the ability to tighten a bolted assembly from only one side. More particularly, the user inserts the bolted attachment through a hole between two components. The nut, including its retained washer, is threaded onto the opposite end of the shaft until the spikes engage the surface of the second component. At this point, since the washer adjacent to the nut is attached to the nut, the tightening of the bolt causes the nut to bear into the washer. The spikes on the washer inhibit rotation of the washer and nut, thus holding the nut in place as the bolt is tightened. Hence, the bolted assembly can be tightened from one side, making attachment of rack assemblies easier and quicker. 
     Since the nut in the above discussion is not required to interact with a tool, it is possible that, instead of the hexagonal nut shown in the figures, a round nut could be used so as to reduce the desire by the installer to use a tool and potentially damage the painted surface. Also, it may be desirable to form the nut and spiked washer as a integral unit or eliminate the nut altogether and simply thread the inner diameter of the washer. 
     The hardware is manufactured in such a way as to allow the spikes to remain rotationally stationary, while the screw (bolt) and nut are tightened. In this way, the paint is displaced by the spike locally without disturbing the adjacent painted surfaces, thus preventing an annular ring of paint removal. Referring to  FIGS. 7A-7E , the installation of a fastener according to the present invention is shown.  FIG. 7A  shows the initial touchdown of the spiked washer  22  onto the painted surface  50 . As the fastener is tightened, the floating gap between the head  14  and the washer is eliminated ( FIG. 7B ). Further tightening of the fastener causes the spikes be begin to penetrate the painted surface  20 , displacing the paint  54  ( FIG. 7C ). The fastener is tightened until the spikes penetrate through the painted surface and into the base metal  52  ( FIG. 7D ).  FIG. 7E  illustrates how the displaced painted coating  54  forms a seal against the side surfaces of the spikes  26 . As a result, the present invention provides a corrosion resistant seal without the need for separate anti-corrosion chemical pastes. 
     Although the preferred embodiment is a conical shaped spike, such as the one shown in  FIG. 9A , it should be apparent from the above discussion that a pyramidal (three, four or more sided) structure can be used as the spike provided the tip is designed to penetrate and displace the painted coating as it extends into the base metal.  FIG. 9C  shows an example of a pyramidal shaped spike. Furthermore, while a pointed spike is preferable, the spike can instead form a knife edge, such as the linear edge shown in  FIG. 9B . The knife edge is designed to dig into the painted coating during tightening, displacing the paint and penetrating into the base metal. 
     Also, it is preferable for the bolt head  14  and the nut  36  to have a base portion  15  that is flared out ward as shown in  FIG. 8 . This produces a full thrust bearing force acting on the washer and spikes as the bolt and nut are tightened. That is, the tightening force is transmitted axially into the spikes (shown by the arrow). As such, the penetrating of the painted surface by the spikes is more efficient since less force it transmitted to the surrounding portion of the washer. Also, there is less of a tendency for the tightening forces to produce distortion of the washer from its planar arrangement. Distortion can lead to the spikes failing to dig into the painted coating and, instead, “skipping” on the surface. 
     The present invention provides a system for use in “ganging” equipment enclosures together, while at the same time providing a continuous and reliable path for electrical ground faults, high frequency leakage currents, and electrically bonding multiple enclosures together to form an extension of the “ground plane”. 
     The present invention can also be used to electrically bond loose sheet metal accessories such as doors, tops, sides, etc. It eliminates the need to mask studs or screw landings pre-paint. 
     Variations, modifications and other implementations of what is described herein will occur to those of ordinary skill in the art without departing from the spirit and scope of the invention. Accordingly, the invention is in no way limited by the preceding illustrative description.