US20080138167A1 - Direct Tension Indicating Washers - Google Patents
Direct Tension Indicating Washers Download PDFInfo
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- US20080138167A1 US20080138167A1 US11/875,224 US87522407A US2008138167A1 US 20080138167 A1 US20080138167 A1 US 20080138167A1 US 87522407 A US87522407 A US 87522407A US 2008138167 A1 US2008138167 A1 US 2008138167A1
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- indicating
- washer
- bolt
- direct tension
- tension
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Images
Classifications
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16B—DEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING
- F16B31/00—Screwed connections specially modified in view of tensile load; Break-bolts
- F16B31/02—Screwed connections specially modified in view of tensile load; Break-bolts for indicating the attainment of a particular tensile load or limiting tensile load
- F16B31/028—Screwed connections specially modified in view of tensile load; Break-bolts for indicating the attainment of a particular tensile load or limiting tensile load with a load-indicating washer or washer assembly
Definitions
- the invention relates in general to direct tension indicating and maintaining washers and in particular to direct tension indicating and maintaining washers that maintain bolt tension and/or indicate when the proper bolt tension has been achieved.
- High strength metal bolts, along with their corresponding nuts, when used in metal connections, are almost always intended to be installed so that they are tensioned.
- the tensioning is usually accomplished by turning the nut relative to the bolt a specified amount of rotation or until a certain torque resistance has been reached.
- the tension in the bolt stretches the bolt and compresses the connection plates between the bolt head and nut so the connection plates do not slip relative to each other. It is this slip resistance which holds structures such as bridges and buildings together.
- FIG. 1 is a top view of a conventional direct tension indicating washer 10 , commonly referred to as a DTI.
- the direct tension indicating washer 10 includes a series of protuberances 12 formed on a first surface 14 .
- corresponding indentations 16 are formed in a second surface 18 of the direct tension indicating washer 10 .
- the direct tension indicating washer 10 is manufactured through a stamping operation in which the blank metal washer 10 is placed between a tool 20 and a die 22 . Pressure is applied to the tool 20 (e.g. by a press) and a protrusion 24 on the tool 20 creates the protuberance 12 , and the corresponding indentation 16 , in the direct tension indicating washer 10 as shown hi FIG. 4 .
- the DTI is manufactured so that when the tightening of the bolt forces the protrusions 12 to compress, or reduce height, sufficiently, the bolt is said to have sufficient tension to meet code requirements. Determination of sufficient protrusion compression is accomplished in the field by the attempt to insert a feeler gage of specified thickness (e.g. 0.015′′) into the residual gap between the underside of the bolt head and the first surface 14 of the DTI.
- FIG. 1A shows a feeler gage being placed on a first surface of a direct tension indicating to test bolt tension (the bolt is not shown for clarity).
- the residual DTI gap (the space between the first surface of the direct tension indicating washer and the bottom of the bolt head) is said to be, on average, of dimension less than the thickness of the feeler gage, and is therefore judged acceptable.
- Conventional direct tension indicating washers are manufactured so that surfaces 14 and 18 are parallel and perpendicular to the longitudinal axis of the bolt which they are made to fit on, that is when the bolt is inserted through the inner diameter.
- Embodiments of the invention include a direct tension indicating washer including: a first surface having a discrete protuberance formed thereon; a second surface having a discrete indentation formed opposite the protuberances; and an indicating material positioned in the indentation, wherein the indicating material has a cured skin on an outside of the indicating material and a liquid core in an interior of the indicating material.
- FIG. 1 is a top view of a conventional direct tension indicating and maintaining washer
- FIG. 1A is a perspective view of the use of a feeler gage to test bolt tension
- FIG. 2 is a cross-sectional view of the direct tension indicating and maintaining washer shown in FIG. 1 taken along line 2 - 2 ;
- FIGS. 3 and 4 illustrate a process for creating the protuberances/indentations in the conventional direct tension indicating and maintaining washer
- FIG. 5 is a cross-sectional view of a direct tension indicating and maintaining washer in accordance with a first embodiment of the invention
- FIG. 6 illustrates a process for forming the direct tension indicating and maintaining washer shown in FIG. 5 ;
- FIGS. 7-9 illustrate the state of the direct tension indicating and maintaining washer during the installation process
- FIG. 10 illustrates the state of the direct tension indicating and maintaining washer after a decrease in bolt elongation
- FIG. 11 is a graph of bolt tension versus bolt elongation when using the conventional direct tension indicating and maintaining washer shown in FIGS. 1-2 ;
- FIG. 12 is a graph of bolt tension versus bolt elongation when using the direct tension indicating and maintaining washer shown in FIG. 5 ;
- FIG. 13 is a top view of direct tension indicating washer in an alternative embodiment of the invention.
- FIG. 14 is a cross-sectional view taken along line 14 - 14 of FIG. 13 ;
- FIG. 15 is an enlarged view of a portion of the direct tension indicating washer of FIG. 14 ;
- FIGS. 16-21 illustrate the state of the direct tension indicating washer of FIG. 13 during the installation process
- FIG. 22 is a graph of bolt tension versus bolt elongation when using the conventional direct tension indicating washer shown in FIGS. 1-2 ;
- FIG. 23 is a graph bolt tension versus bolt elongation when using the direct tension indicating washer shown in FIG. 13 ;
- FIG. 24 is a cross-sectional view of a direct tension indicating and maintaining washer in yet another embodiment of the invention.
- FIGS. 25A-25E illustrate emission of indicating material with increased bolt tension
- FIGS. 26A-26E illustrate emission of indicating material with increased bolt tension in an alternate embodiment.
- FIG. 5 is a cross-sectional view of the direct tension indicating and maintaining washer of the present invention shown generally at 30 .
- the direct tension indicating and maintaining washer is similar to the conventional washer shown in FIG. 1 in that a first surface 14 includes protuberances 12 and the second surface 18 includes indentations 16 .
- the direct tension indicating and maintaining washer 30 has an opening formed therein having an inner diameter wall 31 .
- the inner diameter wall 31 meets the second surface 18 at an inner diameter edge 32 .
- the direct tension indicating and maintaining washer 30 has an outer diameter having an outer diameter wall 33 .
- the outer diameter wall 33 meets the second surface 18 at outer diameter edge 34 .
- the inner diameter edge 32 lies in a plane different from the plane of the outer diameter edge 34 .
- the direct tension indicating and maintaining washer 30 has a conical cross section. It is understood that other geometries may be used.
- FIG. 6 illustrates a step in the process of making the direct tension indicating and maintaining washer 30 .
- the protuberances 12 and indentations 16 are formed as described above with respect to FIGS. 3 and 4 .
- the direct tension indicating and maintaining washer 30 is placed between a second tool 40 and a second die 42 .
- the second die includes recess 44 for receiving the protuberances 12 formed on the first surface of the direct tension indicating and maintaining washer 30 .
- Pressure is applied to the tool 40 and the direct tension indicating and maintaining washer is formed into the conical shape shown in FIG. 5 .
- FIG. 6 illustrates a metal stamping manufacturing process
- other processes such as metal machining or metal casting, may be used to form the direct tension indicating and maintaining washer 30 .
- the metal product will be heat treated by quenching and tempering after forming to produce the required spring-like load/deformation properties.
- the direct tension indicating and maintaining washer 30 is made from carbon steel, but stainless steel and other alloy products and non ferrous metals may also be used.
- FIGS. 7-9 illustrate the state of the direct tension indicating and maintaining washer 30 during the installation process.
- FIG. 7 illustrates the placement of the direct tension indicating and maintaining washer 30 adjacent to a bolt head 50 which is threaded to a nut 52 (shown in FIG. 10 ).
- stage 1 where the bolt is at rest.
- the direct tension indicating and maintaining washer 30 is flattened as shown in FIG. 8 .
- stage 2 the protuberances 12 on the first surface 14 of the direct tension indicating and maintaining washer 30 have not been fully compressed.
- the DTI gap the distance between the first surface 14 and the bottom of the bolt head, is designated as x.
- the direct tension indicating and maintaining washer 30 has been flattened so that the inner diameter edge and the outer diameter edge lie in the same plane, the direct tension indicating and maintaining washer 30 maintains its resiliency and will tend to return to its original conical shape when the bolt tension is released.
- the protuberances 12 are compressed and tightening is discontinued when the DTI gap is at or below a predetermined distance y.
- the bolt installer knows that the bolt tension is equal to or greater than the required minimum. This state is identified as stage 3 and is shown in FIG. 9 .
- the tension may now be tested with a feeler gage as shown in FIG. 1A .
- FIG. 10 illustrates the state of the direct tension indicating and maintaining washer 30 as external loads, metal to metal deformation, or seating in of the bolt, vibration, temperature and other influences cause the bolt to tend to lose elongation.
- the direct tension indicating and maintaining washer 30 due to its resilient nature, pushes against the bottom of the bolt 50 and maintains tension on the bolt. Accordingly, the direct tension indicating and maintaining washer 30 not only indicates when a predetermined bolt tension has been achieved upon bolt installation but maintains bolt tension even as the bolt tension would tend to decline during the life of the bolt/nut assembly.
- FIG. 11 is a graph of bolt tension versus bolt elongation for a bolt/nut assembly using the conventional direct tension indicating washer 10 shown in FIG. 1 .
- Bolt elongation refers to the increase in bolt length due to tension on the bolt.
- any reduction in the bolt elongation due to vibration, temperature, etc. will cause the bolt tension to tend to decline until ultimately, the bolt tension is zero or close to zero (point B).
- FIG. 12 is a graph of bolt tension versus bolt elongation for a bolt/nut assembly using the direct tension indicating washer 30 shown in FIG. 5 .
- the numerals 1 - 4 in FIG. 12 correspond to states 1 - 4 illustrated in FIGS. 7-10 .
- any decrease in bolt elongation will cause a reduction in bolt tension (from A to a minimum level).
- the bolt tension will be maintained at a minimum level 4 by the force applied by virtue of the resilient nature of the direct tension indicating washer 30 .
- FIG. 13 is a top view of a direct tension indicating washer 60 in an alternative embodiment of the invention.
- the direct tension indicating washer 60 is similar to the direct tension indicating washer 10 shown in FIG. 1 in that protuberances 12 are formed on a first surface 14 and corresponding indentations 16 are formed on a second surface 18 .
- the direct tension indicating washer 60 also includes channels 62 that lead from each indentation 16 to the outer diameter of the direct tension indicating washer 60 .
- the indentation 16 is filled with an indicating material 64 as shown in detail in FIG. 15 .
- the direct tension indicating washer 60 is manufactured in a process similar to the direct tension indicating washer 30 . A tool and die are used to stamp the protuberances 12 , indentations 16 and channels 62 into a blank washer.
- the direct tension indicating washer 60 may be formed from carbon steel, but stainless steel, nonferrous metals, and other alloy products may also be used.
- the indicating material 64 is an extrudable, elastomeric solid material such as colored silicone or other materials such a butadiene urethane.
- FIGS. 16-21 illustrate the state of the direct tension indicating washer 60 as a bolt 50 is tightened on the direct tension indicating washer 60 .
- the bolt is placed through an opening in the center of the direct tension indicating washer 60 .
- This state is identified as stage 1 in FIG. 16 .
- the bottom of the bolt head contacts the protuberances 12 and begins to compress the protuberances towards the first surface 14 as shown in FIG. 17 .
- FIG. 18 is an enlarged view of one of the indentations 16 illustrating that the force exerted by the protuberance 12 on the indicating material 64 forces the indicating material into channel 62 .
- This state is identified in FIG. 17 as stage 2 .
- FIG. 19 illustrates the state of the direct tension indicating washer 60 when the bolt 50 has been tightened to a predetermined tension.
- the protuberances 12 have been compressed into the indentations 16 by a distance sufficient to force the indicating material 64 completely through the channel 62 so that the indicating material 64 appears at the outer diameter of the direct tension indicating washer 60 .
- FIG. 20 shows the change in volume of the protuberances 12 from stage 1 to stage 3 . The change in volume of the indentations 16 is calibrated to the volume of channel 62 .
- FIG. 21 is an enlarged view of one of the protuberances 12 and the channel 62 when the predetermined bolt tension has been achieved. As shown in FIG. 21 , the indicating material 64 has been forced through the channel 62 and exits the channel at the outer diameter of the direct tension indicating washer 60 .
- FIG. 22 is a graph of bolt tension versus bolt elongation when using a convention direct tension indicating washer such as that shown in FIG. 1 .
- the desired bolt tension is shown at point B.
- the bolt installer has no indication that the desired bolt tension has been reached and continues to tighten the bolt past the desired bolt tension B.
- FIG. 23 is a graph of bolt tension versus bolt elongation when using the direct tension indicating washer 60 shown in FIGS. 13-14 .
- the numerals 1 - 3 on the graph of FIG. 23 correspond to stages 1 - 3 shown in FIGS. 16-21 .
- the indicating material 64 will appear at the outer diameter of the direct tension indicating washer 60 and the bolt installer knows to discontinue tightening of the bolt. If the extruded indicating material has worn away over time, and confirmation of bolt tension is needed, a feeler gage may be used to confirm adequate bolt tension as shown in FIG. 1A .
- FIG. 24 is a cross sectional view of another embodiment of the invention.
- the direct tension indicating washer 70 in FIG. 24 combines the features of direct tension indicating washer 30 and direct tension indicating washer 60 described above. Accordingly, the direct tension indicating washer 70 both maintains tension by using a conical washer body but also includes the channel 62 and indicating material 64 for immediate detection of the proper bolt tension.
- the inner diameter edge 32 lies in a plane different than the plane of the outer diameter edge 34 .
- FIGS. 25A-25E illustrates emission of the indicating material with increased bolt tension.
- FIGS. 26A-26E illustrate emission of indicating material with increased bolt tension in an alternate embodiment.
- the indicating material has compressibility and modified polymerization to control the release of indicating material through the channel.
- the indicating material in FIGS. 26A-26E is made more compressible than typical silicone.
- the compressibility is achieved by formulating and then energetically mixing the silicone under an inert blanket of nitrogen in such a way as to deposit micro bubbles of nitrogen into the silicone.
- inert blanket of nitrogen in such a way as to deposit micro bubbles of nitrogen into the silicone.
- ultra-dry air may be used. These micro-bubbles have the property of being compressible within the liquid silicone, while not affecting the curing properties of the silicone.
- Modified polymerization generates a cured skin over the compressible silicone in the indentation.
- Most moisture/heat cured silicones have the property of curing from the outside surface inward without stopping, thereby resulting, after a complete cure, in uniform properties all the way through the cured and solid elastomeric silicone.
- Embodiments of the invention use silicone with an additive material mixed into the liquid silicone which has, when triggered by heat or infrared radiation, the effect of terminating the polymerization process. This process results in the polymerization of about 1 millimeter of thickness, leaving the remaining silicone core encapsulated in liquid form, ready to compress and then explode out in liquid form.
- the silicone is cured by the addition of a platinum based catalyst containing an amine or sulphur based molecular sieve which has the capability of poisoning the curing reaction when activated by heat.
- a platinum based catalyst containing an amine or sulphur based molecular sieve which has the capability of poisoning the curing reaction when activated by heat.
- the compressible silicone is deposited in the indentation.
- the compressible silicone is then capped right away with a second fast curing skin which can be any of a large number of materials, sprayed of otherwise deposited on top of the compressible silicone underneath.
- the indentation is then flash cured by heat or Ultraviolet Light (UV) so that the compressible silicone underneath stops curing.
- UV Ultraviolet Light
- FIGS. 26A-26E When this combination of skinned over and liquid core of compressible silicone is used, the onset of silicone appearance at the periphery of the DTI is delayed as shown in FIGS. 26A-26E .
- FIGS. 26A-26D As shown in FIGS. 26A-26D , as the bolt tension increases from 0 to 0.9 Ps, the silicone indicating material is not emitted through the channel right to the end. This is due to the compressibility of the silicone and the cured skin on the outside of the indicating material. At a particular bolt pretension about 90-95% of the intended bolt calibration load, the silicone appearance on the outside is climactic and dramatic as shown in FIG. 26E , effectively alerting the installer that the correct bolt pretension has been achieved.
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- General Engineering & Computer Science (AREA)
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- Bolts, Nuts, And Washers (AREA)
Abstract
A direct tension indicating washer including: a first surface having a discrete protuberance formed thereon; a second surface having a discrete indentation formed opposite the protuberances; and an indicating material positioned in the indentation, wherein the indicating material has a cured skin on an outside of the indicating material and a compressible, liquid core in an interior of the indicating material. When the bolt tension reaches a predetermined level, the liquid cores erupts through the cured skin causing a climactic and dramatic appearance of the indicating material about an edge of the washer.
Description
- This application claims the benefit of U.S. provisional patent application Ser. No. 60/874,457 filed Dec. 12, 2006, the entire contents of which are incorporated herein by reference.
- The invention relates in general to direct tension indicating and maintaining washers and in particular to direct tension indicating and maintaining washers that maintain bolt tension and/or indicate when the proper bolt tension has been achieved.
- High strength metal bolts, along with their corresponding nuts, when used in metal connections, are almost always intended to be installed so that they are tensioned. The tensioning is usually accomplished by turning the nut relative to the bolt a specified amount of rotation or until a certain torque resistance has been reached. The tension in the bolt stretches the bolt and compresses the connection plates between the bolt head and nut so the connection plates do not slip relative to each other. It is this slip resistance which holds structures such as bridges and buildings together.
-
FIG. 1 is a top view of a conventional directtension indicating washer 10, commonly referred to as a DTI. The directtension indicating washer 10 includes a series ofprotuberances 12 formed on afirst surface 14. As shown inFIG. 2 ,corresponding indentations 16 are formed in asecond surface 18 of the directtension indicating washer 10. As shown inFIGS. 3 and 4 , the directtension indicating washer 10 is manufactured through a stamping operation in which theblank metal washer 10 is placed between atool 20 and adie 22. Pressure is applied to the tool 20 (e.g. by a press) and a protrusion 24 on thetool 20 creates theprotuberance 12, and thecorresponding indentation 16, in the directtension indicating washer 10 as shown hiFIG. 4 . - The DTI is manufactured so that when the tightening of the bolt forces the
protrusions 12 to compress, or reduce height, sufficiently, the bolt is said to have sufficient tension to meet code requirements. Determination of sufficient protrusion compression is accomplished in the field by the attempt to insert a feeler gage of specified thickness (e.g. 0.015″) into the residual gap between the underside of the bolt head and thefirst surface 14 of the DTI.FIG. 1A shows a feeler gage being placed on a first surface of a direct tension indicating to test bolt tension (the bolt is not shown for clarity). If the attempt to insert the feeler gage is unsuccessful, that is, the inspector cannot insert the feeler gage into the gap half way radially around the DTI circumference between the DTI protuberances, the residual DTI gap (the space between the first surface of the direct tension indicating washer and the bottom of the bolt head) is said to be, on average, of dimension less than the thickness of the feeler gage, and is therefore judged acceptable. Conventional direct tension indicating washers are manufactured so thatsurfaces - Conventional direct tension indicating washers, though well suited for their intended purposes, have several drawbacks. First, the process of attempting to insert the feeler gage into the DTI gap is time consuming and must be done after the bolt installer has stopped the tightening process. Second, over time, bolt tension declines as the bolt/nut threads seat into the mating steel surfaces and as external loads shake the connections and try to pry the bolt/nut apart. This problem is especially prominent in connections that are subject to vibration such as bridges, structures subject to earthquakes, connections supporting moving cranes and other equipment, etc. As the bolt tension declines, so does the clamping force and the capacity to carry external loads by resistance to slip. The conventional direct
tension indicating washer 10 is flat and has the disadvantage that, after bolt installation, theprotrusions 12 are essentially flattened inelastically and will not spring back to their original positions if the bolt begins to loose tension. - Embodiments of the invention include a direct tension indicating washer including: a first surface having a discrete protuberance formed thereon; a second surface having a discrete indentation formed opposite the protuberances; and an indicating material positioned in the indentation, wherein the indicating material has a cured skin on an outside of the indicating material and a liquid core in an interior of the indicating material.
- Referring now to the drawings wherein like elements are numbered alike in the several Figures:
-
FIG. 1 is a top view of a conventional direct tension indicating and maintaining washer; -
FIG. 1A is a perspective view of the use of a feeler gage to test bolt tension; -
FIG. 2 is a cross-sectional view of the direct tension indicating and maintaining washer shown inFIG. 1 taken along line 2-2; -
FIGS. 3 and 4 illustrate a process for creating the protuberances/indentations in the conventional direct tension indicating and maintaining washer; -
FIG. 5 is a cross-sectional view of a direct tension indicating and maintaining washer in accordance with a first embodiment of the invention; -
FIG. 6 illustrates a process for forming the direct tension indicating and maintaining washer shown inFIG. 5 ; -
FIGS. 7-9 illustrate the state of the direct tension indicating and maintaining washer during the installation process; -
FIG. 10 illustrates the state of the direct tension indicating and maintaining washer after a decrease in bolt elongation; -
FIG. 11 is a graph of bolt tension versus bolt elongation when using the conventional direct tension indicating and maintaining washer shown inFIGS. 1-2 ; -
FIG. 12 is a graph of bolt tension versus bolt elongation when using the direct tension indicating and maintaining washer shown inFIG. 5 ; -
FIG. 13 is a top view of direct tension indicating washer in an alternative embodiment of the invention; -
FIG. 14 is a cross-sectional view taken along line 14-14 ofFIG. 13 ; -
FIG. 15 is an enlarged view of a portion of the direct tension indicating washer ofFIG. 14 ; -
FIGS. 16-21 illustrate the state of the direct tension indicating washer ofFIG. 13 during the installation process; -
FIG. 22 is a graph of bolt tension versus bolt elongation when using the conventional direct tension indicating washer shown inFIGS. 1-2 ; -
FIG. 23 is a graph bolt tension versus bolt elongation when using the direct tension indicating washer shown inFIG. 13 ; -
FIG. 24 is a cross-sectional view of a direct tension indicating and maintaining washer in yet another embodiment of the invention; -
FIGS. 25A-25E illustrate emission of indicating material with increased bolt tension; and -
FIGS. 26A-26E illustrate emission of indicating material with increased bolt tension in an alternate embodiment. -
FIG. 5 is a cross-sectional view of the direct tension indicating and maintaining washer of the present invention shown generally at 30. The direct tension indicating and maintaining washer is similar to the conventional washer shown inFIG. 1 in that afirst surface 14 includesprotuberances 12 and thesecond surface 18 includesindentations 16. The direct tension indicating and maintainingwasher 30 has an opening formed therein having aninner diameter wall 31. Theinner diameter wall 31 meets thesecond surface 18 at aninner diameter edge 32. The direct tension indicating and maintainingwasher 30 has an outer diameter having anouter diameter wall 33. Theouter diameter wall 33 meets thesecond surface 18 atouter diameter edge 34. Theinner diameter edge 32 lies in a plane different from the plane of theouter diameter edge 34. In the exemplary embodiment shown inFIG. 5 , the direct tension indicating and maintainingwasher 30 has a conical cross section. It is understood that other geometries may be used. -
FIG. 6 illustrates a step in the process of making the direct tension indicating and maintainingwasher 30. First, theprotuberances 12 andindentations 16 are formed as described above with respect toFIGS. 3 and 4 . Second, the direct tension indicating and maintainingwasher 30 is placed between asecond tool 40 and asecond die 42. The second die includesrecess 44 for receiving theprotuberances 12 formed on the first surface of the direct tension indicating and maintainingwasher 30. Pressure is applied to thetool 40 and the direct tension indicating and maintaining washer is formed into the conical shape shown inFIG. 5 . - Although
FIG. 6 illustrates a metal stamping manufacturing process, there are other processes, such as metal machining or metal casting, may be used to form the direct tension indicating and maintainingwasher 30. In some cases, the metal product will be heat treated by quenching and tempering after forming to produce the required spring-like load/deformation properties. In an exemplary embodiment, the direct tension indicating and maintainingwasher 30 is made from carbon steel, but stainless steel and other alloy products and non ferrous metals may also be used. -
FIGS. 7-9 illustrate the state of the direct tension indicating and maintainingwasher 30 during the installation process.FIG. 7 illustrates the placement of the direct tension indicating and maintainingwasher 30 adjacent to abolt head 50 which is threaded to a nut 52 (shown inFIG. 10 ). The conditions shown inFIG. 7 are identified asstage 1 where the bolt is at rest. As thebolt 50 is tightened by turning itsnut 52, the direct tension indicating and maintainingwasher 30 is flattened as shown inFIG. 8 . At this state, identified asstage 2, theprotuberances 12 on thefirst surface 14 of the direct tension indicating and maintainingwasher 30 have not been fully compressed. The DTI gap, the distance between thefirst surface 14 and the bottom of the bolt head, is designated as x. Although the direct tension indicating and maintainingwasher 30 has been flattened so that the inner diameter edge and the outer diameter edge lie in the same plane, the direct tension indicating and maintainingwasher 30 maintains its resiliency and will tend to return to its original conical shape when the bolt tension is released. As thebolt 50 is further tightened, theprotuberances 12 are compressed and tightening is discontinued when the DTI gap is at or below a predetermined distance y. At this point, the bolt installer knows that the bolt tension is equal to or greater than the required minimum. This state is identified asstage 3 and is shown inFIG. 9 . The tension may now be tested with a feeler gage as shown inFIG. 1A . -
FIG. 10 illustrates the state of the direct tension indicating and maintainingwasher 30 as external loads, metal to metal deformation, or seating in of the bolt, vibration, temperature and other influences cause the bolt to tend to lose elongation. As shown inFIG. 10 , the direct tension indicating and maintainingwasher 30, due to its resilient nature, pushes against the bottom of thebolt 50 and maintains tension on the bolt. Accordingly, the direct tension indicating and maintainingwasher 30 not only indicates when a predetermined bolt tension has been achieved upon bolt installation but maintains bolt tension even as the bolt tension would tend to decline during the life of the bolt/nut assembly. -
FIG. 11 is a graph of bolt tension versus bolt elongation for a bolt/nut assembly using the conventional directtension indicating washer 10 shown inFIG. 1 . As the bolt is tightened, the bolt tension and the bolt elongation increase as shown inFIG. 11 until the bolt installer is satisfied that the proper tension is achieved at point A. Bolt elongation refers to the increase in bolt length due to tension on the bolt. As shown inFIG. 11 , any reduction in the bolt elongation (due to vibration, temperature, etc.) will cause the bolt tension to tend to decline until ultimately, the bolt tension is zero or close to zero (point B). -
FIG. 12 is a graph of bolt tension versus bolt elongation for a bolt/nut assembly using the directtension indicating washer 30 shown inFIG. 5 . As the bolt is tightened, the bolt tension and the bolt elongation increase as shown inFIG. 12 until the bolt installer is satisfied that the proper tension is achieved at point A. The numerals 1-4 inFIG. 12 correspond to states 1-4 illustrated inFIGS. 7-10 . Subsequently, any decrease in bolt elongation will cause a reduction in bolt tension (from A to a minimum level). However, the bolt tension will be maintained at aminimum level 4 by the force applied by virtue of the resilient nature of the directtension indicating washer 30. -
FIG. 13 is a top view of a directtension indicating washer 60 in an alternative embodiment of the invention. The directtension indicating washer 60 is similar to the directtension indicating washer 10 shown inFIG. 1 in that protuberances 12 are formed on afirst surface 14 and correspondingindentations 16 are formed on asecond surface 18. The directtension indicating washer 60 also includeschannels 62 that lead from eachindentation 16 to the outer diameter of the directtension indicating washer 60. Theindentation 16 is filled with an indicatingmaterial 64 as shown in detail inFIG. 15 . The directtension indicating washer 60 is manufactured in a process similar to the directtension indicating washer 30. A tool and die are used to stamp theprotuberances 12,indentations 16 andchannels 62 into a blank washer. Other processes, such as metal machining or metal casting may be used to form the directtension indicating washer 60. In some cases, the metal product will be heat treated by quenching and tempering after forming to produce the required spring-like load/deformation properties. In an exemplary embodiment, the directtension indicating washer 60 is made from carbon steel, but stainless steel, nonferrous metals, and other alloy products may also be used. The indicatingmaterial 64 is an extrudable, elastomeric solid material such as colored silicone or other materials such a butadiene urethane. -
FIGS. 16-21 illustrate the state of the directtension indicating washer 60 as abolt 50 is tightened on the directtension indicating washer 60. As shown inFIG. 16 , the bolt is placed through an opening in the center of the directtension indicating washer 60. This state is identified asstage 1 inFIG. 16 . As thebolt 50 is tightened, the bottom of the bolt head contacts theprotuberances 12 and begins to compress the protuberances towards thefirst surface 14 as shown inFIG. 17 .FIG. 18 is an enlarged view of one of theindentations 16 illustrating that the force exerted by theprotuberance 12 on the indicatingmaterial 64 forces the indicating material intochannel 62. This state is identified inFIG. 17 asstage 2. -
FIG. 19 illustrates the state of the directtension indicating washer 60 when thebolt 50 has been tightened to a predetermined tension. When the desired bolt tension is achieved, theprotuberances 12 have been compressed into theindentations 16 by a distance sufficient to force the indicatingmaterial 64 completely through thechannel 62 so that the indicatingmaterial 64 appears at the outer diameter of the directtension indicating washer 60.FIG. 20 shows the change in volume of theprotuberances 12 fromstage 1 tostage 3. The change in volume of theindentations 16 is calibrated to the volume ofchannel 62.FIG. 21 is an enlarged view of one of theprotuberances 12 and thechannel 62 when the predetermined bolt tension has been achieved. As shown inFIG. 21 , the indicatingmaterial 64 has been forced through thechannel 62 and exits the channel at the outer diameter of the directtension indicating washer 60. -
FIG. 22 is a graph of bolt tension versus bolt elongation when using a convention direct tension indicating washer such as that shown inFIG. 1 . The desired bolt tension is shown at point B. The bolt installer, however, has no indication that the desired bolt tension has been reached and continues to tighten the bolt past the desired bolt tension B.FIG. 23 is a graph of bolt tension versus bolt elongation when using the directtension indicating washer 60 shown inFIGS. 13-14 . The numerals 1-3 on the graph ofFIG. 23 correspond to stages 1-3 shown inFIGS. 16-21 . When the desired bolt tension is achieved at point B, the indicatingmaterial 64 will appear at the outer diameter of the directtension indicating washer 60 and the bolt installer knows to discontinue tightening of the bolt. If the extruded indicating material has worn away over time, and confirmation of bolt tension is needed, a feeler gage may be used to confirm adequate bolt tension as shown inFIG. 1A . -
FIG. 24 is a cross sectional view of another embodiment of the invention. The directtension indicating washer 70 inFIG. 24 combines the features of directtension indicating washer 30 and directtension indicating washer 60 described above. Accordingly, the directtension indicating washer 70 both maintains tension by using a conical washer body but also includes thechannel 62 and indicatingmaterial 64 for immediate detection of the proper bolt tension. Theinner diameter edge 32 lies in a plane different than the plane of theouter diameter edge 34. -
FIGS. 25A-25E illustrates emission of the indicating material with increased bolt tension. As shown inFIG. 25 , as bolt tension, P, increases from zero to Ps, the intended calibration tension, the indicating material exits the channel. InFIG. 25A , the indicating material is silicone, which typically cures in the indentation prior to use. When cured, although flexible, the silicone is not compressible. Consequently, as the volume of the indentations becomes smaller as the protuberance is compressed, the silicone begins appearing on the outside at around 70% of the intended bolt pretension, shown as P=0.7 Ps inFIG. 25C . This sometimes confuses bolt installers, and they stop tightening at that point. To simply fill the depression with less silicone, does result in a later (higher bolt preload) appearance of silicone, however this practice is risky because of inherent variables in the metal strength the bolt pretension sometimes climbs too high before the silicone is clearly visible. Additional silicone exits the channel as the bolt tension reaches the desired level as shown inFIGS. 25D and 25E . - Accordingly, in alternate embodiments of the invention, a different indicating material is used in the indentations.
FIGS. 26A-26E illustrate emission of indicating material with increased bolt tension in an alternate embodiment. In the embodiment ofFIG. 26 , the indicating material has compressibility and modified polymerization to control the release of indicating material through the channel. - The indicating material in
FIGS. 26A-26E is made more compressible than typical silicone. The compressibility is achieved by formulating and then energetically mixing the silicone under an inert blanket of nitrogen in such a way as to deposit micro bubbles of nitrogen into the silicone. In lieu of nitrogen, ultra-dry air may be used. These micro-bubbles have the property of being compressible within the liquid silicone, while not affecting the curing properties of the silicone. - Modified polymerization generates a cured skin over the compressible silicone in the indentation. Most moisture/heat cured silicones have the property of curing from the outside surface inward without stopping, thereby resulting, after a complete cure, in uniform properties all the way through the cured and solid elastomeric silicone. Embodiments of the invention use silicone with an additive material mixed into the liquid silicone which has, when triggered by heat or infrared radiation, the effect of terminating the polymerization process. This process results in the polymerization of about 1 millimeter of thickness, leaving the remaining silicone core encapsulated in liquid form, ready to compress and then explode out in liquid form.
- In one embodiment, the silicone is cured by the addition of a platinum based catalyst containing an amine or sulphur based molecular sieve which has the capability of poisoning the curing reaction when activated by heat. After the liquid silicone is deposited into the metal DTI, a short interval of time will allow the surface curing to begin, and then an application of heat will terminate the curing process, leaving the liquid compressible core.
- In an alternate embodiment, the compressible silicone is deposited in the indentation. The compressible silicone is then capped right away with a second fast curing skin which can be any of a large number of materials, sprayed of otherwise deposited on top of the compressible silicone underneath. The indentation is then flash cured by heat or Ultraviolet Light (UV) so that the compressible silicone underneath stops curing.
- When this combination of skinned over and liquid core of compressible silicone is used, the onset of silicone appearance at the periphery of the DTI is delayed as shown in
FIGS. 26A-26E . As shown inFIGS. 26A-26D , as the bolt tension increases from 0 to 0.9 Ps, the silicone indicating material is not emitted through the channel right to the end. This is due to the compressibility of the silicone and the cured skin on the outside of the indicating material. At a particular bolt pretension about 90-95% of the intended bolt calibration load, the silicone appearance on the outside is climactic and dramatic as shown inFIG. 26E , effectively alerting the installer that the correct bolt pretension has been achieved. - While preferred embodiments have been shown and described, various modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the present invention has been described by way of illustration and not limitation.
Claims (9)
1. A direct tension indicating washer comprising:
a first surface having a discrete protuberance formed thereon;
a second surface having a discrete indentation formed opposite the protuberance; and
an indicating material positioned in the indentation, wherein the indicating material has a cured skin on an outside of the indicating material and a liquid core in an interior of the indicating material.
2. The direct tension indicating washer of claim 1 wherein the indicating material is mixed under nitrogen prior to being polymerized.
3. The direct tension indicating washer of claim 1 wherein the indicating material is mixed under ultra-dry air prior to being polymerized.
4. The direct tension indicating washer of claim 1 wherein the cured skin is formed by initiating polymerization of the indicating material and terminating the polymerization upon formation of the cured skin.
5. The direct tension indicating washer of claim 4 wherein polymerization is terminated by applying energy to the indicating material.
6. The direct tension indicating washer of claim 5 wherein the indicating material includes a platinum based catalyst.
7. The direct tension indicating washer of claim 1 wherein cured skin is a fast curing skin deposited on top of the liquid core indicating material.
8. The direct tension indicating washer of claim 1 further comprising a channel leading from the indentation to an outer diameter of the direct tension indicating washer.
9. The direct tension indicating washer of claim 1 wherein:
the first surface has a plurality of discrete protuberances formed thereon;
the second surface has a plurality of discrete indentations, each indentation formed opposite one of the protuberances; and
a plurality of channels formed in the second surface, each channel leading from one of the indentations to an outer diameter of the direct tension indicating washer
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
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US11/875,224 US20080138167A1 (en) | 2006-12-12 | 2007-10-19 | Direct Tension Indicating Washers |
US12/891,021 US8002641B2 (en) | 2006-12-12 | 2010-09-27 | Method of making direct tension indicating washers |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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US87445706P | 2006-12-12 | 2006-12-12 | |
US11/875,224 US20080138167A1 (en) | 2006-12-12 | 2007-10-19 | Direct Tension Indicating Washers |
Related Child Applications (1)
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US12/891,021 Division US8002641B2 (en) | 2006-12-12 | 2010-09-27 | Method of making direct tension indicating washers |
Publications (1)
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US20080138167A1 true US20080138167A1 (en) | 2008-06-12 |
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US11/875,224 Abandoned US20080138167A1 (en) | 2006-12-12 | 2007-10-19 | Direct Tension Indicating Washers |
US12/891,021 Active US8002641B2 (en) | 2006-12-12 | 2010-09-27 | Method of making direct tension indicating washers |
Family Applications After (1)
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US12/891,021 Active US8002641B2 (en) | 2006-12-12 | 2010-09-27 | Method of making direct tension indicating washers |
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US (2) | US20080138167A1 (en) |
Cited By (11)
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WO2010135175A2 (en) * | 2009-05-19 | 2010-11-25 | Applied Bolting Technology | Direct tension multi-color indicating washers |
WO2013103444A1 (en) * | 2012-01-04 | 2013-07-11 | Applied Bolting Technology | Creep limiting direct tension indicating washer |
US20140004738A1 (en) * | 2011-01-03 | 2014-01-02 | Wolfgang B. Thoerner | Pole terminal |
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US9239071B2 (en) | 2014-03-18 | 2016-01-19 | Robert E. Stewart | Direct tension indicator plate and assembly |
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US20110014986A1 (en) | 2011-01-20 |
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