Hybrid washer

A hybrid washer has an essentially disk-shaped body having an outer ring, an inner ring, and a bore extending through the inner ring. The outer ring has an engagement surface having a plurality of wedges with each wedge having a raised edge that extends radially and perpendicularly from a longitudinal axis projecting through the bore. The inner ring has a pair of spaced-apart essentially flat surfaces in overlying relation with one another. The wedges form a plurality of crests contoured to frictionally engage a mating surface from a locking washer to fix the locking washer against the hybrid washer.

TECHNICAL FIELD

The subject disclosure is directed to new and improved hybrid washer for use in a fastening system. The hybrid washer includes an inner ring that has the configuration of a typical conventional washer and an outer ring that has the configuration of a locking washer with an engagement surface. The hybrid washer can be made through conventional methods, including conventional metal fabrication methods, or through powder metallurgy.

BACKGROUND ART

Conventional washers are disc shaped objects that include a pair of essentially parallel, flat surfaces with a central hole for a screw shank. The essentially flat characteristic of the parallel surfaces does not facilitate the engagement of one washer to another washer for locking purposes. The conventional washers can be manufactured from a strip blank that is fed to pass several forming or punching stations. The punching stations can utilize various upper and lower tools. In some arrangements, the pattern of teeth can be formed on and can cover, substantially, an upper surface. A pattern of cams can formed on and can cover, substantially, the lower surface of the washer.

These conventional washer fabrication processes have several disadvantages and problems. For example, undesired displacements can occur between the stations during feeding in the die arrangement to cause the formation of defective washers. In some instances, the total amount of blank material can be quite high. Furthermore, there can be restrictions related to the cam and teeth cover on each side of the washers, which decreases the possibility of forming load bearing surfaces. Also, the outer periphery can be punched out and can receive a sharp edge, which causes problems in the further processing of the washer.

Another type of washer is known as a locking washer. Such washers can be used in a locking system in which the washers are arranged in a pair with cam pattern sides facing and engaging each other. The main cam surface inclination can be larger than the pitch of the threads to cause a positive and efficient locking of a fastening element.

One particular type of locking washer arrangement involves a locking washer having teeth on one side and cams on the other side. The teeth can engage with a surface of a screw head, nut or an element to be attached. One possible shape is a leaning pyramidal shape. The teeth can extend, radially, on the locking washer surface. The other side of the known lock washers can have a cam pattern.

In some applications, locking washers are preferred over conventional washers. However, locking washers can have certain disadvantages, particularly involving excessive wear. For these reasons, there is a need for an improved washer.

DISCLOSURE OF INVENTION

In various implementations, a hybrid washer has an essentially disk-shaped body having an outer ring, an inner ring, and a bore extending through the inner ring. The outer ring has an engagement surface having a plurality of wedges with each wedge having a raised edge that extends radially and perpendicularly from a longitudinal axis projecting through the bore. The inner ring has a pair of spaced-apart essentially flat surfaces in overlying relation with one another. The inner ring is essentially flat from the bore to the outer ring. The wedges form a plurality of crests contoured to frictionally engage a mating surface from a locking washer to fix the locking washer against the hybrid washer.

MODES FOR CARRYING OUT THE INVENTION

The subject disclosure is directed to new and improved hybrid washer for use in a fastening system. The hybrid washer includes an inner ring that has the configuration of a typical conventional washer and an outer ring that has the configuration of a locking washer with an engagement surface. The hybrid washer can be made through conventional methods, including conventional metal fabrication methods, or through powder metallurgy.

The detailed description provided below in connection with the appended drawings is intended as a description of examples and is not intended to represent the only forms in which the present examples can be constructed or utilized. The description sets forth functions of the examples and sequences of steps for constructing and operating the examples. However, the same or equivalent functions and sequences can be accomplished by different examples.

References to “one embodiment,” “an embodiment,” “an example embodiment,” “one implementation,” “an implementation,” “one example,” “an example” and the like, indicate that the described embodiment, implementation or example can include a particular feature, structure or characteristic, but every embodiment, implementation or example can not necessarily include the particular feature, structure or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment, implementation or example. Further, when a particular feature, structure or characteristic is described in connection with an embodiment, implementation or example, it is to be appreciated that such feature, structure or characteristic can be implemented in connection with other embodiments, implementations or examples whether or not explicitly described.

Numerous specific details are set forth in order to provide a thorough understanding of one or more embodiments of the described subject matter. It is to be appreciated, however, that such embodiments can be practiced without these specific details.

Various features of the subject disclosure are now described in more detail with reference to the drawings, wherein like numerals generally refer to like or corresponding elements throughout. The drawings and detailed description are not intended to limit the claimed subject matter to the particular form described. Rather, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the claimed subject matter.

The disclosure relates to a hybrid washer that can be used within a fastening system. The hybrid washer has all of the advantages of a conventional washer and a locking washer in a single washer. This can eliminate the need to keep two different types of washers for different applications within various types of fastening systems. Further, the hybrid washer can be useful in fastening systems within high vibration environments.

Another advantage of the disclosed subject matter is that the hybrid washer can be made through powder metallurgy processes. These processes can be more efficient than conventional washer fabrication methods because they can use less material and can be made from metal powders that use recycled materials. The use of powder metallurgy processes can allow the hybrid washer to be made from a wider variety of metals and metal alloys, including metals and metal alloys that cannot be fabricated into washers through conventional processes.

Referring toFIG.1, a hybrid washer, generally designated by the numeral100, in accordance with this disclosure is shown. The hybrid washer100has an essentially disk-shaped body110with an outer ring112, an inner ring114, and a bore116extending through the inner ring114. The outer ring112can perform the functions of a locking washer. The inner ring114can perform the functions of a conventional washer.

The outer ring112is bound by a contoured outer edge118and a contoured inner edge120. The contoured outer edge118represents the outer surface of the hybrid washer110and forms an outer rim for the hybrid washer110. The contoured inner edge120represents a boundary between the outer ring112and the inner ring114. The inner ring114is bound on the opposite side by the bore116, which forms an inner rim for the hybrid washer110.

The outer ring112has an engagement surface122that functions as a locking washer engagement surface. The engagement surface122includes a plurality of wedges124. Each wedge124has a raised edge126and lowered edge128. The wedges124are contoured to form a plurality of crests and troughs around the contoured outer edge118of the outer ring112. The crests and troughs can enhance the ability of the outer ring112to engage other surfaces, frictionally.

The wedges124abut one another to form a radial pattern on the engagement surface122. Each raised edge126and lowered edge128extends radially and perpendicularly from a longitudinal axis, generally identified as D inFIGS.2A-2D, projecting through the bore116.

One exemplary wedge130is connected to an abutting wedge132by a face134that extends perpendicularly from the engagement surface122. The face134is bound by the raised edge136on the wedge130, the lowered edge138on the wedge132, the contoured outer edge118, and the contoured inner edge120.

The inner ring114has a pair of essentially flat surfaces140,142on opposite sides of the hybrid washer disc-shaped body110. The essentially flat surfaces140,142provide the inner ring114with the ability to function as a conventional washer.

The outer ring112and the inner ring114can be made from the same material or different materials. In some embodiments, the outer ring112and the inner ring114are unitary or integral and/or made from the same mass of material.

The outer ring112and the inner ring114can be made from can be made from any suitable material through any suitable manufacturing method. Suitable materials include flexible, semi-flexible, rigid, or semi-rigid materials. Suitable materials also include metals, ceramics, plastics, and composites. Specifically, suitable materials can include metals.

Suitable manufacturing or fabrication methods generally fall into two categories. The first category of processes include the traditional forging and/or stamping processes in which the hybrid washer is formed from a square piece of wrought steel.

The second category of processes includes powder metallurgy processes, such as powder forging, hot isostatic pressing, metal injection molding, electric current assisted sintering, and additive manufacturing techniques. In such processes, powder metal can be stamped into a blank and put into an oven, so that the particles can be sintered together.

The powder metallurgy processes can be performed efficiently by using powder that contain a significant amount of recycled metal contents and by producing less waste material through the production of net shape or near-net shape products.

Referring now toFIGS.2A-2Dwith continuing reference to the foregoing figures, various embodiments of a fastening system, generally designated by the numerals200A-200D, are shown. The embodiments of the fastening systems200A-200D include hybrid washers210A-21.0D that have the ability to function as either a conventional washer or a locking washer. The hybrid washers210A-210D are essentially identical to the hybrid washer100shown inFIG.1.

The fastening systems200A-200D include the hybrid washers210A-210D, a shank member212, a nut214, and a bearing element216. The shank member212connects the nut214to the bearing element216. The nut214is positioned at one end218of the shank member212. The bearing element216includes a hole220that receives the other end222of the shank member212. In these exemplary embodiments, the shank member212is threaded and the bearing element hole220is configured to receive the threaded shank member212.

Referring toFIG.2A, an embodiment of the fastening system200A is shown in which the hybrid washer210A functions like a conventional washer between the nut214and the bearing element216. The shank member212inserts through a bore224A in the hybrid washer210A. The bore224A is essentially identical to the bore116shown inFIG.1.

In this exemplary embodiment, a bottom surface226A of the hybrid washer210A abuts an upper surface228of the hearing element216. The hybrid washer bottom surface226A is an essentially flat surface that is essentially identical to the flat surface142shown inFIG.1.

Unlike known fastening system that include a conventional washer, the fastening system200A can be configured to have an engagement surface230A frictionally engaging the nut214to provide an additional locking capability within the fastening system200A. The frictional engagement of the engagement surface230A against the nut214can lock or fix the shank member212into place between the nut214and the bearing element216. The engagement surface230A can be essentially identical to the engagement surface122shown inFIG.1.

Referring toFIG.2B, another embodiment of the fastening system200B is shown in which the hybrid washer210B functions like a locking washer between the nut214and the bearing element216. The shank member212inserts through a bore224B in the hybrid washer210B. The bore224B is essentially identical to the bore116shown inFIG.1.

In this exemplary embodiment, the hybrid washer210B is positioned in an upside down configuration in which an essentially flat hybrid washer bottom surface226B engages the nut214. The upper surface228of the bearing element216abuts an engagement surface230B for the hybrid washer210B to lock or to fix the shank member212in place.

The engagement surface230B of the hybrid washer210B can deform the upper surface228either permanently or temporarily when the hybrid washer210B is made from a material that is harder than the material for which the bearing element216is made. The configuration is particularly useful when the bearing element216is made from wood or plastic and the hybrid washer210B is made from a metal that is harder than wood or plastic.

Referring toFIG.2C, another embodiment of the fastening system200C is shown. The fastening system200C is particularly adapted for applications in which there is a significant amount of vibration. In this exemplary embodiment, a hybrid washer210C and a locking washer232C are positioned between the nut214and the bearing element216. The shank member212inserts through both the hybrid washer210C and the locking washer232C.

The hybrid washer210C is with its engagement surface230C facing the nut214and a mating surface234C on the locking washer232C facing the bearing element216. The engagement surface230C abuts the mating surface234C, so that the surfaces are frictionally engaged.

The engagement surface230C and the mating surface234C can be contoured with a plurality of crests and troughs in the same manner in which the engagement surface122shown inFIG.1is contoured. In some embodiments, the mating surface234C is contoured to form a plurality of crests for inserting into troughs on the engagement surface230C. Similarly, the mating surface234C can be contoured to form a plurality of troughs for receiving crests on the engagement surface230C to lock the hybrid washer210C against the locking washer232C. In such embodiments, the engagement surface230C and the mating surface234C are interlocking, so that the hybrid washer210C does not slip against the locking washer232C, particularly when the environment includes a significant amount of vibration.

It should be understood that fastening system200C can be configured with the hybrid washer210C and the locking washer232C in opposite positions. In such embodiments, the hybrid washer210C abuts the nut214and the locking washer232C abuts the bearing element216. The engagement surface230C abuts and frictionally engages the mating surface234C.

Referring toFIG.2D, another embodiment of the fastening system200D is shown. Like the embodiment shown inFIG.2C, the fastening system200D is particularly adapted for applications in which there is a significant amount of vibration. Unlike the embodiment shown inFIG.2C, the fastening system200D includes two identical hybrid washers210D positioned with the engagement surfaces230D facing one another in abutment and in frictional engagement.

Referring toFIG.3, another embodiment of a hybrid washer, generally designated by the numeral300, in accordance with this disclosure is shown. Like the hybrid washer100shown inFIG.1, the hybrid washer300has an essentially disk-shaped body310with an outer ring312, an inner ring314, and a bore316extending through the inner ring314. The outer ring312can perform the functions of a locking washer. The inner ring314can perform the functions of a conventional washer.

Unlike the embodiment shown inFIG.1, the hybrid washer300includes a recess318separating the outer ring312from the inner ring314. In this exemplary embodiment, the recess318is essentially circular and is positioned between the outer ring312and the inner ring314. The outer ring312, the inner ring314, the bore316, and the recess318are essentially concentric with one another. The recess318allows for easier tooling.

Referring toFIG.4with continuing reference to the foregoing figures, a method400for making a hybrid washer in accordance with the described subject matter is shown. In this exemplary embodiment, the hybrid washer is essentially identical to the hybrid washer100shown inFIG.1and the hybrid washers210A-210D shown inFIGS.2A-2D.

At401, a metal powder is formed. In this exemplary embodiment, the metal powder can be formed of multiple metals to facilitate the formation of a hybrid washer that is formed from a metal alloy.

At402, a metal powder is compacted into a washer preform. In this exemplary embodiment, the compacting step can be performed through any conventional or unconventional powder metallurgy compacting step. In some embodiments, Step402is performed in a flexible mold.

At403, the washer preform can be sintered to form a hybrid washer having an essentially disk-shaped body having an outer ring, an inner ring, and a bore extending through the inner ring, the outer ring including an engagement surface with a plurality of wedges forming a plurality of crests and troughs, the inner ring including a pair of spaced-apart essentially flat surfaces in overlying relation with one another.

SUPPORTED FEATURES AND EMBODIMENTS

The detailed description provided above in connection with the appended drawings explicitly describes and supports various features of a hybrid washer. By way of illustration and not limitation, supported embodiments include an apparatus comprising: a hybrid washer having an essentially disk-shaped body having an outer ring, an inner ring, and a bore extending through the inner ring, the outer ring having an engagement surface having a plurality of wedges with each wedge having a raised edge that extends radially and perpendicularly from a longitudinal axis projecting through the bore, and the inner ring includes a pair of spaced-apart essentially flat surfaces in overlying relation with one another, wherein the wedges form a plurality of crests contoured to frictionally engage a mating surface from a locking washer to fix the locking washer against the hybrid washer.

Supported embodiments include the foregoing apparatus, wherein the locking washer mating surface includes a plurality of troughs and the hybrid washer outer ring engagement surface crests are contoured to fit into the troughs.

Supported embodiments include any of the foregoing apparatus, wherein the hybrid washer includes metal.

Supported embodiments include any of the foregoing apparatus, wherein the metal is selected from the group consisting of carbon steel, spring steel, stainless steel, copper, brass, aluminum, titanium, iron, bronze, zinc, silicon bronze, Inconel, Monel, and Hastelloy.

Supported embodiments include any of the foregoing apparatus, wherein the metal is formed through a powder metallurgy process.

Supported embodiments include any of the foregoing apparatus, further comprising a recess separating the outer ring from the inner ring.

Supported embodiments include any of the foregoing apparatus, wherein the recess is essentially circular and the outer ring, the inner ring, the bore, and the recess are essentially concentric with one another.

Supported embodiments include a system, a method and/or means for implementing any of the foregoing apparatus or portions thereof.

Supported embodiments include a fastening system comprising: a shank member, a nut positioned at one end of the shank member, a bearing element receiving the other end of the shank member, and a hybrid washer having an essentially disk-shaped body having an outer ring, an inner ring, and a bore extending through the inner ring, the outer ring including an engagement surface with a plurality of wedges forming a plurality of crests and troughs, the inner ring including a pair of spaced-apart essentially flat surfaces in overlying relation with one another, wherein the shank member inserts through the hybrid washer inner ring bore.

Supported embodiments include the foregoing fastening system, further comprising: a locking washer having a mating surface for frictionally engaging the hybrid washer outer ring engagement surface to lock or to fix the shank member in place.

Supported embodiments include any of the foregoing fastening systems, wherein the hybrid washer is a first hybrid washer and the locking washer is a second hybrid washer having a mating surface with a plurality of wedges contoured to form a plurality of crests for inserting into the first hybrid washer engagement surface troughs and a plurality of troughs for receiving the first hybrid washer engagement surface crests to lock the first hybrid washer against the second hybrid washer.

Supported embodiments include any of the foregoing fastening systems, wherein the first hybrid washer is identical to the second hybrid washer.

Supported embodiments include any of the foregoing fastening systems, wherein the hybrid washer outer ring engagement surface frictionally engages the bearing element.

Supported embodiments include any of the foregoing fastening systems, wherein the hybrid washer outer ring engagement surface frictionally engages the nut.

Supported embodiments include any of the foregoing fastening systems, wherein the hybrid washer includes metal.

Supported embodiments include any of the foregoing fastening systems, wherein the metal is selected from the group consisting of carbon steel, spring steel, stainless steel, copper, brass, aluminum, titanium, iron, bronze, zinc, silicon bronze, Inconel, Monel, and Hastelloy.

Supported embodiments include any of the foregoing fastening systems, wherein the metal is formed through a powder metallurgy process.

Supported embodiments include any of the foregoing fastening systems, wherein the hybrid washer includes a recess separating the hybrid washer outer ring from the hybrid washer inner ring.

Supported embodiments include any of the foregoing fastening systems, wherein the recess is essentially circular and the hybrid washer outer ring, the hybrid washer inner ring, the hybrid washer bore, and the recess are essentially concentric with one another.

Supported embodiments include an apparatus, a method, and/or means for implementing any of the foregoing fastening systems or portions thereof.

Supported embodiments include a method of producing a hybrid washer, the method comprising: compacting a metal powder into a washer preform, and sintering the washer preform to form a hybrid washer having an essentially disk-shaped body having an outer ring, an inner ring, and a bore extending through the inner ring, the outer ring including an engagement surface with a plurality of wedges forming a plurality of crests and troughs, the inner ring including a pair of spaced-apart essentially flat surfaces in overlying relation with one another.

Supported embodiments include the foregoing method, further comprising: forming a metal powder.

Supported embodiments include any of the foregoing methods, further comprising: forming a metal powder having a plurality of metals to facilitate the formation of a metal alloy in the sintering step.

Supported embodiments include any of the foregoing methods, wherein each hybrid washer engagement surface trough is configured to receive a corresponding crest on a locking washer mating surface and each hybrid washer engagement surface crest is configured to insert into a corresponding trough on the locking washer mating surface.

Supported embodiments include any of the foregoing methods, wherein the locking washer is identical to the hybrid washer.

Supported embodiments include any of the foregoing methods, wherein the compacting step is performed in a flexible mold.

Supported embodiments include an apparatus, a system, and/or means for implementing any of the foregoing methods or portions thereof.

Supported embodiments can provide various attendant and/or technical advantages in terms of improved efficiency and/or savings with respect to providing a single washer than can function as both a conventional washer and as a locking washer. The washer can be particularly adapted for use in fastening systems in high vibration environments.

Supported embodiments include a hybrid washer that can be made through powder metallurgy processes to reduce or to eliminate waste material. Supported embodiments include a hybrid washer that can be made with metal powders that include a substantial amount of recycled material.

The detailed description provided above in connection with the appended drawings is intended as a description of examples and is not intended to represent the only forms in which the present examples can be constructed or utilized.

It is to be understood that the configurations and/or approaches described herein are exemplary in nature, and that the described embodiments, implementations and/or examples are not to be considered in a limiting sense, because numerous variations are possible. The specific processes or methods described herein can represent one or more of any number of processing strategies. As such, various operations illustrated and/or described can be performed in the sequence illustrated and/or described, in other sequences, in parallel, or omitted. Likewise, the order of the above-described processes can be changed.

Although the subject matter has been described in language specific to structural features and/or methodological acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above. Rather, the specific features and acts described above are presented as example forms of implementing the claims.