Abstract:
A washer-lock washer is disclosed that can be used with a fastener. In one form the washer-lock washer is integrally connected. In another form the washer-lock washer is joined together from two separate pieces. The washer-lock washer may be provided with additional locking features, which would include nubs, indentations, protrusions or cones. This latter concept of the present invention can also be incorporated into a separate lock washer. In another form, the lock washer portion is a separate piece with additional locking features. In another form the washer-lock washer is combined with a fastener. In another form, the washer portion of the washer-lock washer can be welded in place to the mating part or secured by some other means. The washer-lock washer and washer lock-washer fastener combination expedites assembly of products using the same, and can be used to hold together parts in conjunction with either a threads in one of the parts or a separate nut. Various forms for the locking portion are also disclosed.

Description:
[0001]    This application is a continuation-in-part United States Non-Provisional application claiming priority of and benefit of the filing dates of U.S. Provisional Patent applications Ser. No. 60/935,420, of Aug. 13, 2007 and Ser. No. 61/069,717 of Mar. 17, 2008 by the present inventor Mark L. Kluga and relates to a washer-lock washer unit and methods for making and using the same. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    Heretofore, it has been known to make a plain washer, generally a circular or non-circular disk with a hole or opening in the center, generally to receive a bolt or fastener. It was also known to make a split lock washer, generally a circular or near circular arcuate piece with a hole or opening in the center for the same purpose and a split or slit therein with the adjacent ends offset. These two separate pieces (washer and lock washer) are generally separately formed as by punching or winding around a mandrel from a strip or coil or wire of material, such as steel, and after formed may be heat treated. In use generally the lock washer may be placed on a bolt, or fastener, and then in a separate step, the washer is put on the bolt. The bolt with the lock washer and separate washer thereon are placed into a part to be secured and then threaded into an opening in another part or a nut and tightened to the required tightness. With the prior art washer and lock washer, two separate operations were needed both to form and also just to place the two separate washers on the bolt or fastener. 
       SUMMARY OF THE INVENTION 
       [0003]    The present invention is the creation of a unitary washer-lock washer which can be formed from a coil or strip, in this instance the same strip, of material, such as, for example, steel or non-ferrous material. In the present invention, the washer portion and lock washer portion are formed and integral with or joined to each other. In making, the washer-lock washer may be formed generally at the same time, say as by punching in die on a punch press, and then the washer-lock washer portions are folded over in a die so that the fastener holes in both portions are generally axially aligned. The washer-lock washer structure could be formed by operations in a progressive die or 4-slide die or from a mold or other types of tooling, with for example, the two holes being formed, then the portions&#39; outlines being punched, the slit in the lock washer formed, and in one or more operations, the portions relatively folded over approximately 180° so that the two openings generally axially align. Of course other orders of operation could be used. The portions can then be heat treated and plated as desired. The washer portion can be of any suitable configuration, the normal round, or square (see  FIGS. 16A &amp; 16B ), triangular, rectangular, or other geometric or curved shape, as desired or required. The washer-lock washer may also be formed of initially two separate pieces, formed say at separate times and then joined together by various means, such as stacking, welding, coining, hanging, etc. 
         [0004]    In use in assembling say a manufactured product, the time and operations to place the prior art washer and lock washer on a fastener is essentially cut in half, as the washer-lock washer of the present invention is simultaneously placed on or under the fastener in a single operation, and then the fastener with both washers in place installed into the part to be secured and into the threaded opening or nut and tightened as required. Of course, this procedure could be altered to accommodate the washers located adjacent or under a nut, rather than adjacent the head of or on the fastener. Considerable assembly time and effort can be saved by use of the combined, integral washer-lock washer of the present invention. This construction is a value added product for the end user (be it manufacturer, assembler, end user or re-builder). For example, the time lost when one of the washer or lock washer of the conventional, two separate piece construction, is dropped and has to be picked up or recovered or another put in its place, is eliminated or avoided. Further, customer dissatisfaction which results when the customer discovers its newly purchased machine does not have all the needed washers or lock washers at each location is eliminated or avoided, and any customer questioning of the quality of the remainder of the machine or its assembly avoided. 
         [0005]    Further, the washer-lock washer can be combined with an appropriate size fastener and further assembly time saved by the use of such ready to install in one operation fastener, washer-lock washer combination. 
         [0006]    Objects of the Present Invention 
         [0007]    It is an object of the present invention to develop a combined washer-lock washer. 
         [0008]    Another object is to provide a washer-lock washer which can be placed on a fastener together. 
         [0009]    Yet another object is to develop a washer-lock washer which expedites assembly and reduces the time and effort to place both washers on a fastener. 
         [0010]    Still another object is to provide a washer-lock washer which can be used on a fastener to secure parts together with a threaded opening in one of the parts or a separate threaded nut. 
         [0011]    Yet another object is for the washer portion of the washer-lock washer to be welded to the mating part or secured by some other means. 
         [0012]    Yet another object is to provide a method for manufacturing the washer-lock washer of the present invention. 
         [0013]    Still a further object is to provide a method for forming the washer-lock washer of the present invention. 
         [0014]    Another object is to provide means for using the washer-lock washer of the present invention to more quickly assemble parts together. 
         [0015]    Still a further object is to provide a die or tool for forming the washer-lock washer of the present invention. 
         [0016]    Still a further object of the present is to provide a washer-lock washer, fastener combination, ready for use and/or to be threaded into a threaded opening in a part or nut. 
         [0017]    Yet a further object is to provide the washer-lock washer fastener (be it bolt or nut) combination ready for use, wherein the washers are held in place on the fastener. 
         [0018]    Still a further object is to provide serrations or locking features on the mating surface of the washer-washer lock and/or associated mating surface of the fastener so as to provide further enhanced locking features between the fastener (bolt or nut) and washer-lock washer. 
         [0019]    Yet a further object is to provide serrations or locking features on the mating surface of the washer-lock washer so as to provide further enhanced locking features between the fastened part and washer-lock washer. 
         [0020]    Still a further object is to provide the lock washer portion as a separate item with additional locking features, such as protrusions or cones, not currently provided on prior art lock washers due to their method of manufacture. 
         [0021]    These and other objects of the present invention will become apparent from the following written description and accompanying figures of drawings wherein: 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS  
         [0022]      FIGS. 1A and 1B  are perspective views of a washer-lock washer of the present invention taken from different view points. 
           [0023]      FIGS. 1C ,  1 D,  1 E,  1 F and  1 G are drawings from my first provisional application of a lock washer like that shown in  FIGS. 1A and 1B . 
           [0024]      FIG. 2A  is a schematic plan view of the strips of stock from which the washer-lock washer of the present invention can be progressively made. 
           [0025]      FIG. 2B  is a side elevational view of the strip of stock shown in the last operation of  FIG. 2A  prior to folding. 
           [0026]      FIG. 3A  is a schematic of plan views showing how the washer-lock washer of the present invention can be folded from the strip of stock shown at the right in  FIGS. 2A and 2B . 
           [0027]      FIG. 3B  is a schematic of corresponding elevational views to  FIG. 3A  showing how the lock washer and washer portions can be relatively folded over to form the washer-lock washer of the present invention. 
           [0028]      FIG. 4A  is a schematic plan view of the die or one form of tool for forming the washer-lock washer of the present invention. 
           [0029]      FIG. 4B  is a schematic elevational view of the die for forming the washer-lock washer of the present invention. 
           [0030]      FIG. 5A  is a first schematic arrangement of a series placement of a line of washer-lock washers of the present invention. 
           [0031]      FIG. 5B  is a second schematic arrangement of a more efficient placement of a line of washers angled off depending on the diameters of the washer and lock portions resulting in less waste. 
           [0032]      FIGS. 6A and 6B  are schematic views, similar to  FIG. 5A and 5B , but showing how a “gang” of washer-lock washers of the present invention can be formed. 
           [0033]      FIG. 7A  is an exploded schematic view showing how one part can be secured to a second part having a threaded opening to receive a fastener with a washer-lock washer of the present invention. 
           [0034]      FIG. 7B  is a cross-sectional assembled view of the parts shown in  FIG. 7A . 
           [0035]      FIG. 8A  is an exploded schematic view showing how one part can be secured to a second part with a fastener with a washer-lock washer of the present invention and a threaded nut. 
           [0036]      FIG. 8B  is a cross-sectional assembled view of the parts shown in  FIG. 8A . 
           [0037]      FIG. 9  is a schematic view showing a fastener, washer-lock washer combination of the present invention ready for use with a threaded opening or nut. 
           [0038]      FIGS. 10A , B and C are schematic views showing how the mating surfaces ( FIG. 10A , and/or  FIG. 10C ) of the lock nut portion of the present invention prior to folding can have serrations which would cooperate with associated serrations on a conventional serrated nut or bolt head and/or fastened part to increase the “hold.” 
           [0039]      FIGS. 11A and 11B  are schematic views of other embodiments of the washer-lock washer of the present invention, wherein one or more of washer-lock washer portions are of the star or serrated type in prefold and folded forms. 
           [0040]      FIGS. 12A and 12B  are schematic views of other embodiments of the washer-lock washer of the present invention, wherein one or more of washer-lock washer portions are of the star type in prefold and folded forms. 
           [0041]      FIGS. 13A and 13B  are schematic views of still other embodiments of the washer-lock washer of the present invention, wherein one or more of washer-lock washer portions are of the star type in a prefold and folded forms. 
           [0042]      FIGS. 14A and 14B  are schematic views of yet other embodiments of the lock washer-lock washer of the present invention, wherein one or more of washer-lock washer portions are of the star type in prefold and folded forms. 
           [0043]      FIGS. 15A and 15B  illustrate two components, a nut and washer-lock washer prior to assembly to form a fastener in the form of a nut, washer-lock washer combination shown in the latter figure. 
           [0044]      FIGS. 16A and 16B  show a non-round washer portion joined integral with a round lock washer portion forming a square washer-lock washer of the present invention with the lock washer having “hold” enhancing protrusions ( FIG. 16A ) and the washer having cone-shaped dimples for a similar purpose. 
           [0045]      FIGS. 17A and 17B  show a washer-loc washer similar to  FIGS. 16A and 16B , but with a round washer portion, and the protrusions and cones or dimples for enhanced grip. 
           [0046]      FIGS. 18A and 18B  show a separate lock washer, which could be used separately, or could be joined to a washer portion, that has the enhance grip protrusions on one or both sides. 
           [0047]      FIG. 19  illustrates the method and die or tool used for making the washer shown in  FIGS. 18A and 18B . 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0048]    Referring to  FIGS. 1A ,  1 B,  1 C,  1 D,  1 E,  1 F and  1 G the washer-lock washer  10  of the present invention comprises a washer portion  12  and a lock washer portion  16 , formed and joined together or made integral by the adjacent connecting tab  18  connected to both portions  12  and  16 . Each portion  12  and  16  has an appropriate sized (diameter) opening  20  and  22 , respectively, to receive a fastener or bolt, which may be of a conventional type, with which it is to be used. See  FIGS. 7A to 9  and  15 B. The lock washer portion  16  may be of the split or other type, and, in this instance, has a split  24 , with its respective ends  26  and  28  relatively axially offset from one another. Note the connected end  28  is closely adjacent the tab  18  to maximize the length of the offset portion and its free end  24 . 
         [0049]    As noted in  FIGS. 16A and 16B  the washer portion of the washer-lock washer of the present invention is not restricted to the normal round profile, but could have a non-round profile, such as rectangular, square (as shown), triangular or other curved (but flat or planer) shape. Likewise the interior opening could also be of a non-round shape, such as like any mentioned above, and for example, square to receive a square portion of a carriage bolt. 
         [0050]    It should be understood that such non-round washer portion lock washers could be manufactured and used in a manner similar to that described below for the washer-lock washer  10  of the present invention with the round style washer portion  12 . 
         [0051]    Referring to  FIG. 2A and 2B , the washer-lock washer  10  of the present invention, includes the others just described, and in one manner, can be formed from a strip  30  of stock material, e.g., steel, alloy, steel, stainless, bronze, plastic. Of course, other materials could be used. Moving from left to right as indicated by the arrow  30 A, the openings  20  and  22  are punched or formed; then the profiles  36  and  38  of portions  12  and  16  as formed; then the split  24  formed and the end  26  offset. Now the above and/or following order of operations could be altered and still fall within the present invention. These operations could be progressive for an individual blank, and or carried on simultaneously for several flanks. 
         [0052]    Referring to  FIG. 3A  (plan view) and  3 B (elevation), the part from  FIGS. 2A and 2B  can then be folded over in steps approximately 180° so that the openings  20  and  22  generally axially align. 
         [0053]    Now referring to  FIG. 4A and 4B , the washer-lock washer  10  of the present invention can be formed, for example, by progressively forming on a die  31  as by punching, the holes  20  and  22 , then portions of the outlines  36  and  38  of the respective washer portions  12  and  16 , including the connecting tab  18 , forming the slit  24  forming up, over and closing the portions  12  and  16  (folding them relatively over), and forming the remainder of the portions  36  and/or  38  to cut off or free one washer-lock washer  10 . The strip is then moved or indexed to the left here relative the die  31  to complete the next washer-lock washer. For example, the die  31 , like that shown in  FIG. 4A and 4B , can be used to progressively form the washer-lock washer of the present invention, carrying out the steps illustrated in  FIGS. 2A ,  2 B,  3 A and  3 B and listed in  FIGS. 4A and 4B . The washer-lock washer  10  of the present invention could also be formed by other means, such as 4-slide die. The washer-lock washer  10  could also be formed of any material which a conventional washer is made such as steel, various alloys, stainless steel, bronze, brass, monel, copper, etc. 
         [0054]    The washer-lock washer of the present invention could be formed of plastic, or say nylon, as by injection molding. Other high strength materials or plastics could be used such as pvc, polyesters, etc. 
         [0055]    Further, the washer-lock washer of the present invention could also have a plurality serrations  39  (or alternatively raised or hollow elements) on either side or both sides of the lock washer or washer portions to accommodate complementary serrations formed on the mating surface(s) of the associated fastener (bolt or nut) or adjacent surface of one of the parts being secured. See  FIG. 10  for an example of this construction, before the folding operation. 
         [0056]    Other type lock washer construction portions could be utilized as the lock washer portion of the lock washer-lock washer of the present invention, such as internal and external type star washers. See  FIG. 11A and 11B  to  14 A and  14 B for various combinations of washer-lock washers having one or more internal and/or external star provisions, some with round profiles. 
         [0057]    In  FIG. 11A  (flat) and  FIG. 11B  (folded), the washer portion  12 A has a round (but may have a semi-round) internal hole  20 A and an external star  36 A, while the smaller lock portion  16 A has both internal  22 A and external star  38 A configuration, with the portions  12 A and  16 A joined by the tab  18 A. In  FIG. 12A  (flat) and  FIG. 12B  (folded), the washer portion  12 B has a round (or semi-round) internal hole  20 B and an external smooth profile  36 B, while the smaller lock portion  16 B has both internal  22 B and external star  38 B configuration, with the portions  12 B and  16 B joined by the tab  18 B. In  FIG. 13A  (flat) and  FIG. 13B  (folded), the washer portion  12 C has a round (or semi-round) internal hole  20 C and an external star  36 C, while the smaller lock portion  16 C has a round (or semi-round) internal hole  22 C and external star  38 C configuration, with the portions  12 C and  16 C joined by the tab  18 C. In  FIG. 14A  (flat) and  FIG. 14B  (folded) the washer portion  12 D has a round (or semi-round) internal hole  20 D and a smooth external edge  36 D, while the smaller lock portion  16 D has a round (or semi-round) internal hole  22 D and an external star  38 D configuration, with the portions  12 D and  16 D joined by the tab  18 D. It should be understood that other combinations of smooth internal/external edge and star internal/external edges could be used and such would fall within the scope of the present invention. It should be further understood that the washer portion, could also have a non-round profile, such as square, rectangular, triangular, etc. as desired. 
         [0058]    While only a single washer-lock washer  10  is being formed on the strip  30  as shown in  FIGS. 5A and 5B , they could be “gang” formed several at a time on a wider strip  30 A, as shown in  FIG. 6A and 6B . Of course, even more rows than two could be provided on even a wider strip. It should be noted that by angularly aligning the washer in accord with the external diameters of the portions  12  and  16 , results in a more compact arrangement and less waste, similarly to the savings of  FIGS. 5B  over  5 A or  FIG. 6B  over  FIG. 6A  arrangements. Of course the strips  30  in  FIGS. 6A and 6B  would utilize a “grouped” or multiple die having multiple provision of the die shown in  FIGS. 4A and 4B . 
         [0059]      FIGS. 7A and 7B  and  8 A and  8 B illustrate how the washer-lock washer  10  of the present invention can be placed on a fastener  40  and used to secure parts  42  and  44  together, as by screwing the fastener  40  into a threaded opening  46  ( FIG. 7B ) and/or with a threaded nut  48  ( FIG. 8B ). It should be understood that the washer-lock washer  10  of the present invention, when a nut  48  is utilized, could be either adjacent the head  52  of the fastener  40  and/or the nut  48 . 
         [0060]    In the present invention, assembly is speeded as the steps of placing both a conventional washer and a conventional lock washer on or under a fastener is reduced and cut in half or more as both a washer-lock washer are placed with a single operation. Also in the present invention, damage to the work piece  42  ( FIG. 7A ) caused by use of the lock washer alone is eliminated. 
         [0061]    Further time can be saved by providing the assembler with an appropriate sized fastener or bolt (selected diameter, length and thread size) with the washer-lock washer already assembled thereon. Slight misalignment of the washer portion  12  and lock washer portions  16  and their openings  20  and  22 , say during or after forming, could be used to hold the washer-lock washer  10  into the fastener  40 , adjacent the head  52 , with a very slight interference fit, until utilized during assembly. Alternatively the fastener could have a slightly recessed portion  53  between the threads  55  and head  52  to permit the washer-lock washer to freely rotate, but yet be retained on the fastener. See  FIG. 9 . 
         [0062]    Likewise a washer-lock washer  10  of the present invention could be attached to a nut  48 A, as by inserting the same onto a nut extension  48 B and then peaning or coining over the extension  48 B to permit the washer to relatively rotate but yet be held or captured onto the nut. See  FIGS. 15A and 15B . 
         [0063]    In alternative the washer-lock washer could be with openings  20  or  22  and/or for one of the washers  12  or  16  may be made somewhat smaller so as to hold the washers  12  and  16  onto the fastener  40  adjacent the head  52  or extension  53  on the nut  48 A. 
         [0064]    Thus, with the fastener washer-lock washer combination of  FIGS. 9  or  15 , assembly is speeded as the washer-lock washer be it  10  (or one of the other versions), is already on the fastener, and the time to put the prior separate washer and lock washer in place is reduced. Further, should the combination be dropped, as it is still even bigger, it is easier to see and find, and also easier to see that if not put in place, is missing and needs to be put in place. Further, only one piece (the sanitary washer-lock washer), as opposed to two separate pieces, need be purchased, inventoried, handled, inspected, and assembled. 
         [0065]    Thus, with the present invention the perceived quality of the assembled product is enhanced as the likelihood of a washer or lock washer being missing is greatly reduced, along with speeding assembly. 
         [0066]    As shown in  FIGS. 16A and 16B , the washer portion  120  could be non-round and this instance square. If the desired the corners  122  could be reduced instead of sharply cut as shown. The lock washer portion  160  has several protrusions  162  to help enhance its grip. These could be vertically oriented upward as shown with reference to  FIG. 16A . As shown in  16 B the washer portion  160  could have grip enhancing cones or dimples  164  formed therein. Of course such a washer-lock washer could be formed with or without either protrusions  160  or cones or dimples  164 . The protrusions or cones or dimples could be formed in the punching or stamping operations. Now the protrusions  162  and/or cones or dimples  164  could be used in conjunction with a round washer portion  120 A, as is shown in  FIGS. 17A and 17B . 
         [0067]    Further, the lock washer portion  160  could be separately formed and used alone; like a conventional lock washer, or could be joined as discussed herein to a washer portion to form a washer-lock washer combination, say as by welding or other techniques mentioned herein. This washer portion  160  would have the protrusions  162 , which differentiate it from a conventional lock washer. 
         [0068]    The single lock washers shown in  FIGS. 18A and 18B  could be made by the method and die  181  or tool shown in  FIG. 19 . Therein a strip  180  is progressively punched to form the inner and outer profiles (at  182 ) then punched to form the three or more downward extrusions or protrusions, say at a 120° apart, downwardly (at  184 ) then punched to form the upward extrusions or protrusions upwardly (at  186 ), then sheared to form the lock washer split (at  188 ) and finally punched away from the strip (at  190 ). Of course the lock washer could also be multiply ganged punched. The strip  180  would be moved along progressively in a die having the above described operations in this listed or other order. While three extensions or protrusions  162  are shown on each side, there could be more such as four or five on each side. Generally there would not be less than three per side. The protrusions could be provided just on one or the other side or as shown in  FIG. 18 , on both sides. 
         [0069]    In a simplified form shown in  FIG. 19  the die and method could be used to form the protrusions on the inside diameter or alternatively on the outer diameter or both of the single lock washer. The single lock washer protrusions, such as  162 , provides increased locking features and actions to engage the fastener, nut, and/or work piece. The tooling stages are: 
         [0070]    1. form the basic profile and pierce the hole ( 182 ); 
         [0071]    2. form extrusions in one direction ( 184 ); 
         [0072]    3. form extrusions in opposite direction ( 186 ); 
         [0073]    4. shear lock (split) ( 188 ); and 
         [0074]    5. punch completed profile away (cut-off)( 190 ). 
         [0075]    While the washer and lock washer portions can be joined by an integral tab, the washer and lock washer could be secured to each other, the fastener (bolt or nut) or one of the pieces or parts to be secured) together as by welding, say spot welding to minimize heat and distortion or by other means. Or, two separate pieces (washer and lock washer) may be joined by other methods or means as mentioned earlier. 
         [0076]    While several embodiments of the apparatus and method of the present invention have been illustrated and described, it should be understood that such does not limit the scope of invention and that equivalent elements and steps will fall within the scope of the attached or subsequently to be attached claims in any successor application.