Bonding fastener assembly for electrical grounding

1. A fastener assembly for securing two or more structures and providing electrical grounding to the secured structures after attachment, the fastener assembly comprising:

a fastener with a head having a first surface for engagement by a fastening tool, second surface on the opposite side of the head from the first surface, and a shaft extending outward from the second surface of the head; and

an annular electrically conductive washer rotatably disposed about the shaft and rotatable relative to the second surface of the fastener head, the washer having an inner diameter, an outer diameter, a first surface and a second surface located on the opposite side of the washer from the first surface, the first surface being positioned adjacent to the second surface of the head, the combination of the first surface of the washer and the second surface of the head providing a low friction interface so that the head can rotate relative to the washer, and approximately six substantially identical pointed projections extending out from the second surface of the washer and formed integrally therewith, the pointed projections adapted to penetrate into the structure being secured;

wherein the projections are conically shaped and substantially equally spaced about the washer at a common radius so that the pointed projections lie substantially on a medial circumference.

2. The fastener assembly of claim 1 , wherein the projections have a height of approximately 0.062 inches and have a tip end with an inclusive angle of between approximately 20 degrees and 120 degrees.

3. The fastener assembly of claim 2 , wherein the inclusive angle is between approximately 30 degrees and 80 degrees.

4. The fastener assembly of claim 3 , wherein the inclusive angle is approximately 60 degrees, and wherein the projection has a Rockwell hardness of approximately 58 on the Rockwell C scale.

5. The fastener assembly of claim 1 , each projection having a height of approximately 0.062 inches and have a tip end with an inclusive angle of approximately 60 degrees, the washer having a thickness of approximately 0.0625 inches.

6. The fastener assembly of claim 1 wherein the shaft includes a non-threaded portion located adjacent to the head, and wherein the washer is located about the non-threaded portion of the shaft and retained on the fastener such that the washer can rotate about the shaft but cannot be readily removed off of the shaft.

7. The fastener assembly of claim 6 wherein the washer is retained on the shaft by the threads.

8. The fastener assembly of claim 1 , wherein the fastener is a bolt and the assembly further comprises a nut, the nut having a first surface for engagement by an attachment tool, and a substantially flat second surface on the opposite side of the nut from the first surface, the second surface of the nut facing the second surface of the head and the second surface of the washer.

9. A fastener assembly for securing two or more structures and providing electrical grounding to the secured structures after attachment, the fastener assembly, the fastener assembly comprising:

a bolt with a head having a first surface for engagement by a fastening tool, second surface on the opposite side of the head from the first surface, and a shaft extending outward from the second surface of the head; and

a first annular electrically conductive washer rotatably disposed about the shaft and rotatable relative to the second surface of the fastener head, the washer having an inner diameter, an outer diameter, a first surface and a second surface located on the opposite side of the washer from the first surface, the first surface being positioned adjacent to the second surface of the head, the combination of the first surface of the first washer and the second surface of the head providing a low friction interface so that the head can rotate relative to the first washer, and a plurality of substantially identical pointed projections extending out from the second surface of the first washer and formed integrally therewith, the pointed projections adapted to penetrate into the structure being secured;

a nut having a first surface for engagement by an attachment tool, and a substantially flat second surface on the opposite side of the nut from the first surface, the second surface of the nut facing the second surface of the head and the second surface of the first washer;

a second annular washer rotatably disposed about the shaft and rotatable relative to the second surface of the nut, the second washer having an inner diameter, an outer diameter, a first surface and a second surface on the opposite side of the second washer from the first surface, the first surface of the second washer being positioned adjacent to the second surface of the nut, and a plurality of substantially identical pointed projections extending out from the second surface of the second washer and formed integrally therewith.

10. The fastener assembly of claim 9 , wherein the second washer is retained on the nut such that the second washer can rotate relative to the nut but cannot be readily removed off of the nut.

11. The fastener assembly of claim 10 , wherein the nut includes a tubular extension that extends out from the second surface of the nut, the distal end of the tubular extension being swaged radially outward to form a lip, the second washer being located between the lip and the second surface of the nut, such that the second washer is retained on the nut by the lip.

12. The fastener assembly of claim 9 , wherein the projections have a height of approximately 0.062 inches and have a tip end with an inclusive angle of between approximately 20 degrees and 120 degrees.

13. The fastener assembly of claim 12 , wherein the inclusive angle is between approximately 30 degrees and 80 degrees.

14. The fastener assembly of claim 13 , wherein the inclusive angle is approximately 60 degrees, and wherein the projection has a Rockwell hardness of approximately 58 on the Rockwell C scale.

15. The fastener assembly of claim 9 , each projection having a height of approximately 0.062 inches and have a tip end with an inclusive angle of approximately 60 degrees, the washer having a thickness of approximately 0.0625 inches.

16. The fastener assembly of claim 9 , wherein the shaft includes a non-threaded portion located adjacent to the head, and wherein the washer is located about the non-threaded portion of the shaft and retained on the fastener such that the washer can rotate about the shaft but cannot be readily removed off of the shaft.

17. The fastener assembly of claim 16 , wherein the washer is retained on the shaft by the threads.

18. A fastener assembly for securing two or more structures and providing electrical grounding to the secured structures after attachment, the fastener assembly comprising:

an electrically conductive bolt with a head having a first surface for engagement by a fastening tool, second surface on the opposite side of the head from the first surface, and a shaft extending outward from the second surface of the head; and

a first annular electrically conductive washer rotatably disposed about the shaft and rotatable relative to the fastener head, the washer having a first surface positioned adjacent to and in electrical contact with the second surface of the head, a second surface located on the opposite side of the washer from the first surface, and a plurality of substantially identical sharp projections extending out from the second surface of the washer and formed integrally therewith, the sharp projections being adapted to penetrate into one of the structures being secured;

an electrically conductive nut having a substantially flat surface facing the second surface of the head and the second surface of the first washer, the nut being adapted to be engaged in electrical contact with the bolt; and

a second annular electrically conductive washer rotatably retained on the nut, the second washer having a first surface positioned adjacent to and in electrical contact with the second surface of the nut, a second surface on the opposite side of the second washer from the first surface, and a plurality of substantially identical sharp projections extending out from the second surface of the second washer and formed integrally therewith, the sharp projections being adapted to penetrate into the other of the structures being secured.

19. A method of forming a fastener assembly according to claim 9 , the fastener for securing two or more structures and providing electrical grounding to the secured structures after attachment, the method comprising the steps of:

providing a fastener according to claim 9 ;

providing an annular washer having an inner diameter, an outer diameter, a first surface and a second surface located on the opposite side of the washer from the first surface;

placing the second surface of the washer on a die having a plurality of cavities formed therein, each cavity with a conically shaped contour and being substantially equally spaced about the washer at a common radius so that the pointed projections lie substantially on a medial circumference;

driving a punch into the first surface of the washer to force a portion of the washer into each cavity, the combination of the punch and cavity forming conical projections on the washer; and

placing the washer on the shaft of the fastener with the first surface of the washer adjacent to the second surface of the head of the fastener to form the fastener assembly.