Abstract: A locking fastener assembly comprising a nut and a washer. The nut and washer each have opposed load bearing surfaces which include a series of annularly extending, slightly inclined faces forming shallow undulations around each surface. The load bearing surface on the nut is generally spherically convex and the load bearing surface on the washer is generally spherically concave. The nut rotates as it is installed while the washer is prevented from rotating so that the undulating bearing surface on the nut slides over the undulating bearing surface on the washer against ever increasing resistance until the assembly is properly seated and the nut is effectively prevented from counter-rotating by interference between opposed, inclined faces. A concave clamping surface is formed on the outer end of the washer on a radially extending flange. The flange flexes when the assembly is installed and resiliently urges the washer against the nut.

Abstract: A ball joint includes a socket that defines an outer surface having multiple, annular, smoothly-curved teeth. A ball is received in the socket, and the socket is received in a recess of a housing. This recess defines complementarily-shaped annular, smoothly-curved teeth. The crests of the teeth are arranged along lines that are angled with respect to the insertion axis such that the teeth of the socket pass over the teeth of the housing without an interference fit therebetween during an early stage of assembly. It is only at the end of assembly that the teeth of the socket mechanically interfere with the teeth of the housing to create the desired snap lock. In one example, the ball joint housing forms a recess that receives a rod. The inner surface of this recess undulates and includes gradually converging surfaces and gradually diverging surfaces with respect to the rod axis.

Abstract: An automotive suspension stabilizer bar includes a fiber-reinforced composite rod having sets of fibers oriented at 0°, +45°, and −45° with respect to the longitudinal axis of the rod. Each end of the rod is secured to a respective light metal arm by first positioning the rod end in a recess in the arm and then crimping the arm about the rod end. The result is a lightweight, corrosion-resistant stabilizer bar.

Abstract: A suspension link assembly for a vehicle suspension system. A preferred form comprises only three different kinds of components. The components are a stud shaft, a sleeve nut and a grommet. In an alternative form a barrel-shaped, molded plastic spacer is added. The link assembly lends itself to partial preassembly off the vehicle assembly line and delivery to the assembler as a kit.

Abstract: A fastener assembly includes (a) a fastening member that includes an out-of-round portion centered about a longitudinal axis and configured for engagement with a torque-transmitting tool, a frustoconical load-bearing surface that extends radially outwardly from the longitudinal axis, and a threaded portion that is centered about the longitudinal axis; (b) a metallic, frustoconical thrust washer having a concave surface positioned adjacent to the load-bearing surface of the fastening member, and a convex surface; and (c) a pressure ring that includes a flange, a frustoconical load-bearing surface formed by the flange and positioned adjacent to the convex surface of the thrust washer, and a frustoconical undersurface oriented to contact a complementary depression in a workpiece.

Abstract: A link assembly for connecting a stabilizer crank arm and a suspension arm in a vehicle suspension system. The link assembly includes a barrel-shaped spacer having dome-shaped opposite ends. The spacer body has an axial bore therethrough which receives a bolt or stud shaft. The spacer spaces the crank arm and suspension system arm. Grommets on opposite ends of the shaft resiliently hold the arms against the spacer.

Abstract: A composite link comprising a fiber reinforced composite tube, an end fitting on each end of the tube and layers of resin impregnated fiber wound over the end fittings and tube. The fiber is laid in a primary layer formed by winding longitudinally over the end fittings and a secondary layer wound transversely around the primary layer and the tube. The tube, fitting and layers of fiber are encased in a layer of shield material such as paint or a polymer, for example.

Abstract: A weathershed for use in a composite insulator includes a molded polymer body. The body configuration is such that the leakage distance across the weathershed is increased, while at the same time the amount of material needed is reduced. This provides a lightweight and easily manufactured weathershed. The weathershed includes a radially curved outer edge which reduces the electric field gradient and also reduces the tendency to trap contaminants.

Abstract: A link assembly for a vehicle control system comprising a spacer molded of glass-filled nylon and a socket housing mounted on each end of the spacer, both socket housings also being molded of glass-filled nylon. Each housing comprises a male socket component and a female socket component which are mirror-image, identical to each other except for complementary male locator protrusions and female locator depressions formed in opposing relationship on mating faces of respective components. The components are ultrasonically welded together to capture opposite ends of the spacer and the ball ends of respective ball studs.

Abstract: A composite link includes a fiberglass body. The body is formed by coating glass fibers with a liquid resin and winding the fibers around a plurality of end pieces or bushings. The end pieces have transition sections for smoothly changing the shape of the composite link and the path of the fibers. The fibers are wound in two layers, a first extending longitudinally of the body and the second transversely and around the first. A shield layer is placed over the fiberglass body.

Abstract: A cable connector for securing the end of a cable includes a body supporting opposed jaws for sliding motion for gripping a cable with a wedge action. A slot in the top wall of the body permits the cable to be loaded from the top of the body. T-shaped guide structures capture the jaws for controlled sliding movement. Separate springs directly and independently bias the jaws toward a closed position. A sturdy latch plate synchronizes the jaw motion and retains the jaws in a cocked, open position ready to receive a cable. The springs are enclosed at the sides of the jaws, and are of substantial length.

Abstract: A composite insulator with a silicone rubber sheath coating the insulator rod between metal fittings. Adjacent the line fitting, at least, a series of weathersheds are mounted on the rod and fastened to the sheath with their hubs in abutting relationship and with one hub abutting the line fitting. Another series of sheds are spaced from each other and from the series of weathersheds having their hubs in abutting relationship.

Abstract: A flanged wheel fastener includes a fastener body having a threaded portion, a load-bearing surface, an out-of-round surface and a flange situated between the load-bearing surface and the out-of-round surface. A cap is disposed over the out-of-round surface and the flange, and an edge portion of the cap is bent around the flange to retain the cap on the fastener body. All portions of the cap are spaced axially away from all portions of the bearing-surface, and the cap is free of welding or adhesive attachment to the fastener body.

Abstract: A plastic fastener for securing moldings to frames in vehicles. The fastener includes minor slots formed in the fastener and adjacent to a coupling structure. The minor slots provide sufficient flexibility to allow the fastener to flex inward under pressure, thereby permitting the coupling structure to move between an engagement position and a retracted position. The fastener is pushed through an opening in the frame. The opening is sized such that the edges of the opening apply pressure to the fastener as it moves through the opening, thereby moving the coupling structure toward its retracted position. When the fastener completely in the opening, the pressure is relieved, and the coupling structure snaps back to its engagement position, thereby engaging the edges of the opening and securing the fastener thereto. The fastener may be removed from the opening by applying sufficient pressure to again move the coupling structure to its retracted position.

Abstract: A ball joint link includes a ball stud having a stud and a ball, a cap mounted on the ball, and a rod. The ball defines a raised annular stem which fits inside a tubular portion of the rod such that the ball stud, the cap and the rod form a self-supporting sub-assembly. This sub-assembly is then placed within a mold, and a molded body is formed around the sub-assembly. A strengthening element can be disposed in the molded body around the ball stud to increase pull out resistance.

Abstract: A ball joint link includes a center tube and a ball stud. A one-piece, thermoplastic, molded housing extends around the ball to form a ball joint and is secured to the tube. The tube and the ball of the ball stud are both insert molded in the housing in a single molding operation, and the housing is formed of a glass-filled nylon that forms the bearing surface for the ball joint.

Abstract: A ball joint link includes a ball stud, a ball cap and a strengthening element that are all insert molded in a thermoplastic body. The strengthening element is disposed around the ball stud and includes a first portion which receives the ball of the ball stud and a second portion which receives the stud of the ball stud. The strengthening element is securely anchored in the body, and the second portion of the strengthening element resists pull out forces tending to remove the ball stud from the ball joint link. The ball cap snaps in place on the ball and is substantially completely embedded within the body. Insert molding methods for forming the ball joint link are disclosed.

Abstract: A free spinning positively locking fastener assembly for threaded joints such as automotive or truck wheel assemblies includes a flanged nut with a retainer washer captured on the nut flange. The washer includes a tab received in a slot of a wheel spindle to permit the washer to move axially and prevent the washer from rotating. A pair of resilient locking clips normally lock the nut to the washer to prevent relative rotation so that neither the nut nor the washer can rotate relative to the spindle. The locking clips are released by engagement of a wrench socket with the wrenching structure of the nut so that the nut can be threaded to a desired position. When the wrench is removed, locking fingers on the clips engage the washer to prevent the nut from rotating. The clips are located at diametrically opposed wrenching flats of the nut, spaced from the corners of the wrenching structure.

Abstract: A cable connector includes a base and two upstanding posts, each carrying a cable retention arm spaced above and parallel to the base. The arms extend in opposite directions, flanking a cable entry slot. The connector is place on a cable with the cable in the entry slot, and the connector is then moved ninety degrees to locate the cable in a cable retention path extending beneath the arms. A clamp plate is moved from the base toward the arms to clamp the cable against the arms. Applications for the connector include a spacer for power distribution cables and splicing two cables together.