Method and a device for the manufacturing of washers and washer for a locking system

[0001] This application is a nationalization under 35 U.S.C. 371 of PCT/SE2006/050165, filed May 30, 2006 and published as WO 2006/130106 A1 on Dec. 7, 2006, which claimed priority under 35 U.S.C. 119 to Sweden Patent Application Serial No. 0501224-0, filed May 31, 2005; which applications and publication are incorporated herein by reference and made a part hereof.

[0002] 1.1 Technical Field

[0003] The present invention relates to a method for the manufacturing of washers according to the inventory part of claim 1.

[0004] The invention further relates to a device for the manufacturing of washers.

[0005] The invention also relates to a washer for a locking system.

[0006] 1.2 Prior Art

[0007] Washers of substantially the kind specified above are previously known and provided for eg bolts or the corresponding fastening elements for locking purposes.

[0008] Two washers are arranged in a pair, substantially as shown in FIG. 1, the cam pattern sides facing and engaging each other, the main cam surface inclination being larger than the pitch of the threads, which causes a positive and efficient locking of the fastening element.

[0009] The washers are manufactured from a strip blank, which is fed to pass several stations, in which forming and/or punching is performed between upper and lower tools, the pattern of teeth being formed on and covering the upper surface and the cam pattern being formed on and covering the lower surface of the washer.

[0010] The final operation is the punching out of the washer outer periphery by an upper punch against the upper surface of the washer. This punching operation has proved to cause severe wear in the outer punch periphery region, which calls for frequent punch exchange, which disturbs the production and lowers the productivity.

[0011] The purpose of the present invention is to provide a solution to the above referenced problems.

[0012] The purpose specified above is obtained by a method according to the attached claim 1.

[0013] Further advantages are offered by what is specified in the dependent claims.

[0029] In FIG. 2, 1 designates a prior art washer having a central hole 1′, on one side 2, a first side and the upper side in the manufacturing process, a pattern of teeth 3 and on the other side 4, a second side and the lower side in the manufacturing process, a pattern of cams 5, both patterns running from the inner periphery 6 of the washer to the outer periphery 7. 7′ designates irregularities, defects, at the outer periphery, these being caused by a punch, as described later.

[0030] In FIG. 3, showing a first embodiment of a washer 1 according to the invention, the washer is formed and provided with a flat surface edge zone 8, i.e. a surface without a pattern of teeth, extending radially outside the pattern of teeth, against which surface the punch is arranged to act upon punching, at least a flat surface edge zone 8 part being present on the washer as punched out.

[0031] The configuration of the washer flat surface edge zone may be such that the flat surface extends on the same level as the top 3′ of the teeth or lower, as shown eg in FIG. 3.

[0032] According to a second embodiment of a washer according to the invention, FIG. 4, the washer is formed with the cam pattern on the upper side in the manufacturing and is cut out against this side. Also in this case the washer is formed and provided with a flat surface edge zone 8 extending radially outside the cam pattern, against which surface the punch is arranged to act upon punching, at least a part of the flat surface being present on the washer as punched out.

[0033] In this case the configuration of the washer flat surface edge zone should be such that the flat zone extends at or below the cam pattern bottom 5′, since the cam patterns of two identical washers facing each other must engage. The washers may be non-identical but this is not advantageous from several points of view.

[0034] In FIGS. 5-9 parts of the prior art process for manufacturing prior art washers is shown. The process comprises feeding a pre-punched washer blank strip 1″ to a forming punching operation A, in which the pattern of teeth 3 is formed by an upper punch A1 and the pattern of cams 5 is formed by a lower punch or die, not shown. For clarity, pre-punching operations as well as an operation for punching out the inner periphery of the washers have been left out. B designates a final punching operation arranged after the forming punching operation, in which final punching operation washers are intend to be punched out against a lower die, not shown, by an upper punch B1. The pattern of teeth formed extends beyond the outer periphery of the finished washer. As can be seen in FIGS. 5 and 7, the punch B1 of the final punching operation comprises a peripheral cutting edge portion 9 in the punching end 10 of the punch, the cutting edge running about a central recess 11 in the punch end and having an annular flat bottom surface 12 provided to act against the pattern of teeth of the washer to be in a cutting action for cutting out the washer as can be seen in FIGS. 5, 7, 8 and 9. The cutting action against the pattern of teeth causes wear of the cutting edge as well as undesired indentations, irregulations, 7′. FIG. 9, in the top parts of the teeth in the peripheral zone of the pattern of teeth. Wear of the cutting edge is especially severe in a pattern of teeth configuration as shown in FIGS. 6, 8 and 9, in which the teeth are closely packed in the circumferential direction of the washer, the teeth following directly one after the other in said direction.

[0035] In FIGS. 10-13 parts of a process according to the invention for manufacturing washers according to the invention is shown, pre-punching operations and inner periphery punching operation having been left out. Also in this case the process comprises feeding a pre-punched washer blank strip 1″ to a forming punch operation F, in which the pattern of teeth 3 is formed by an upper punch F1, and the pattern of cams 5 is formed by a lower punch or die, not shown. According to the invention the upper punch F1 is designed for forming a flat surface edge zone 8 extending radially and running circumferentially outside the pattern of teeth. In a final punching operation G arranged after the forming punching operation, washers are intended to be punched out against a lower die, not shown. According to the invention the punch G1, having a peripheral cutting edge portion 14 running about a central recess 15 in the punch end 1 and having an annular flat bottom surface 17 provided to act against at least an inner part 18 of the flat surface edge zone outside the pattern of teeth in a cutting action, as can be seen in eg FIGS. 12 and 14, whereby a clean punching cut is obtained. In a corresponding way the second embodiment of a washer, FIG. 4, is manufactured for the provision of a clean punching cut.

[0036] The method and the function of the device as well as the washer according to the invention should to a satisfactory extent have been disclosed by the description given above.

[0037] Thus, the washer is formed with a flat surface edge zone 8 extending radially outside the washer side pattern and is punched out by a punch G1 action against this surface, this providing a clean punching cut operation corresponding to a punching operation for eg a flat strip, which operation causes much less wear of the punch cutting edge than if the cut is performed against a surface with a pattern of teeth or cams.

[0038] Above the invention has been described by means of example and preferred embodiments.

[0039] Of course further embodiments and minor changes and additions may be imagined without departing from the basic inventive idea.

[0040] According to preferred embodiments each cam 5 of the cam side 4, FIG. 4 eg, has a main cam surface 5″ provided with an inclination larger that the pitch of the threads, as described earlier, and a steeply, preferably axially, running surface 5′″ connecting two adjacent main cam surface 5″.

[0041] Further according to preferred embodiments each tooth 3, FIG. 3 eg, has a main surface 3″, being inclined contrary to the main cam surfaces in a wedge-like configuration, and a steeply, at least close to axially, running surface 3′″ connecting two adjacent tooth main surfaces 3″.

[0042] Preferably, each cam main surface 5′ is via a steeply running surface 5′″ directly connected to the adjacent main cam surface 5″. Furthermore, each main tooth surface 3″, is via a steeply running surface 3′″ directly connected to the adjacent main tooth surface 3′. Embodiments may, however, be imagined according to which, at least as far as the pattern of teeth is concerned, a certain minor distance, not shown, in the circumferential direction is provided between the teeth. Preferably this distance is less than the tooth extension in the circumferential direction.

[0043] Thus, the invention should not be considered limited to the examples and embodiments shown but may be varied within the scope of the accompanying claims.