Black Decker Inc.

James R Horney

William D Sauerwein

Daniel H Sides, Jr

Steven A Weber

A method for producing an annular composite washer subassembly for use as a `soft` mount for the abrasive disc subassembly of a portable grinder includes first and second relatively movable mold portions with each mold portion having a pair of spring-biased pins therein. A first flat annular washer having a pair of holes is placed over the pins in the first mold portion and a second annular flat washer having a pair of holes is placed over the pins in the second mold portion. The pins of the first mold portion extend through the holes of the first washer to engage the second washer, and, conversely, the pins of the second mold portion extend through the holes of the second washer to engage the first washer. The first and second washers are positionally maintained in their respective mold portions by the pins of the opposite mold portion while a plasticized plastic material is injected into the mold and allowed to solidify between the so-positioned washers to form the composite washer assembly.

Method of producing a composite washer assembly

An annular composite washer assembly provides a 'soft' mount for a tool element subassembly mounted on the threaded output spindle of a portable grinder or other power tool. The composite washer includes a pair of flat annular washers and a molded body therebetween. The body has integrally-molded inner and outer annular bands joined integrally with the inner and outer diameters of the respective washers. A first pair of blind axial pockets, diametrically opposed to one another, extends through the first washer and the body and terminates at the second washer. A second pair of blind axial pockets, diametrically opposed to one another and shifted circumferentially with respect to the first pair of blind axial pockets (preferably by ninety degrees) extends through the second washer, through the body, and terminates at the first washer. A second embodiment includes a first and second set of three equidistantly circumferentially spaced pockets, one set formed through the first washer, and the other set formed through the second washer. The pockets formed through the second washer are shifted circumferentially by approximately 60.degree. with respect to the respective pockets formed through the first washer.

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Cockeysville, MD, United States of America

James R Horney