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KINEMATIC SPRING WASHERS AND COUPLING SYSTEM
The present invention relates to a wavy spring washer with
integral bumps and
grooves to enable the washers to locate with respect to each
other deterministically to
provide more accurate centering and to be less likely to slip
off of each other when
stacked. In addition, the integral bumps and grooves enable the
spring washers to mate
with corresponding bumps or grooves on other components to
deterministically, that is
kinematically, locate them, and to also enable torques and
forces to be transmitted
between components, so the washers act as a spring coupling
between components.
BACKGROUND
Wavy spring washers are a well-known type of spring element that
is widely used
in many applications in place of a cold spring, because they
enable the same spring rate to
be achieved in a much smaller space. Belleville washers are
another type of spring washer
that provides even greater spring force in a small place.
However, spring washers, like
any other washer, do not have centering features, so they can
become non-concentric,
which can cause loads to be borne unevenly. In addition, they
provide only a spring force
function in a single direction. They cannot provide any
locational capability.
If a kinematic coupling system could be incorporated into a wavy
spring washer,
then it would be possible for the washer to achieve its spring
function, and also to locate
itself with respect to other washers in a stack, or to other
components such as those for
which it is providing spring function. Precision three-groove
kinematic couplings, such
as described by coapplicant Slocum (A. Slocum Precision Machine
Design, Prentice Hall,
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1991, Section 7.7), achieve stability, and good overall
stiffness if the normals to the plane
of the contact force vectors bisect the angles of the triangle
formed by the hemispheres
(e.g., balls) that lie in the grooves. To accomplish this effect
in a spring washer requires
the creation of formed grooves and ball-like elements.
It should be noted that a kinematic coupling has been located on
top of a spring
mount, as shown in US Patent #5,678, 944 by co-applicant Slocum
et-al. What is desired
in this case is kinematic coupling that itself is spring
compliant. US Patent #5,769,554 by
co-applicant Slocum shows a method for coupling sand cores where
a kinematic coupling
ball indents itself in vees in sand cores. In addition, pending
US Patents serial number
(XXXXXX) by co-applicant et-al. shows two components effectively
kinematically
coupled with three balls in one component elastic/plastically
deforming three
corresponding grooves in a second component to which it is being
mated, thereby
allowing the components to be kinematically coupled and then
bolted together to have a
tight interface such as would be required for the assembly of
engine components. What is
still needed, however, is a simple springy kinematic element
that can be stamped from
spring steel to kinematically locate itself or other components
with respect to each other,
while providing significant compliance.
OBJECTS OF THE INVENTION
An object of the present invention, accordingly, is to provide a
spring washer with
kinematically effective sets of three grooves and three
bumps.
A further object is to size the bumps and grooves such that
stacks of washers can
be nested where the top of a groove and mate with the bottom
side of a groove, and the
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top of a bump can mate with the bottom side of a bump to achieve
an increase in the
spring rate while maintaining alignment of the washers with
respect to each other.
A further object is to size the bumps and grooves such that
stacks of washers can
be nested where the top of a groove and mate with the bottom
side of a bump to achieve a
decrease in the spring rate while maintaining alignment of the
washers with respect to
each other.
Another object of the invention is to enable the washers to be
deterministically, that is
kinematically, located with respect to a component to which they
are providing spring
support to, by having bumps or grooves on the washers engaging
bumps or grooves on
the component.
Still a further object of the invention is for the bumps to have
a larger radius at the
inside diameter of the washer than at the outside diameter to
minimize stresses in the
washer.
Still a further objective of the invention is for the washers to
function as a
coupling element between two components, such that the kinematic
location capability in
combination with the spring washer effect creates a compliant
coupling between the two
components.
Still a further objective of the invention is to function as a
slip clutch, whereby the
bumps and grooves that engage corresponding elements do so at an
angle, and thus if a
drive torque is exceeded, they can slide to disengage, and the
motion can be
accommodated by compression of the spring washer.
Other and further objects will be explained hereinafter and are
more fully
delineated in the appended claims.
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SUMMARY
In summary, the invention includes a wavy spring washer with
bumps on each of
the peaks and each of the valleys of a wavy spring washer, such
that the tops of a bump
can act in effect like protrubances, and the bottoms of a bump
can act in effect like
grooves, such that the washers can be stacked upon each other in
phase where
protuberances mate with the grooves to enable a stack of such
washers to act in parallel as
springs to increase the stiffness of a stack of washers, or if
rotated with respect to each
other and stacked up each other where protuberances mate with
the grooves to enable a
stack of such washers to act in series as springs to decrease
the stiffness of a stack of
washers and increase the amount of spring travel, where the
mating of protrubances and
grooves acts to keep the washers located in a deterministic
manner. When the washers
are used to support components that have similar effective
grooves and protrubances, the
washers can deterministically couple to the components thereby
establish defined six
degree of freedom location between the components and the
washers, but allowing
motion according to the spring rate of the washers; and in this
manner, the washers can
act as a flexible coupling between components such that when two
sets of washers are
utilized at two different coupling lengths of two nominally
concentric shafts, one shaft
can be deterministically be located with respect to the other,
with only desired axial
compliance between the two shafts. The axial compliance provided
between the two
shafts enables the mating protrubances and grooves, which
nominally contact at six points
at each interface to the components, enables the washers to act
as slip clutches, thereby
enabling one shaft to transfer torque to another shaft, yet the
axial compression capability
of the spring washer allows a bump to ride out of a groove and
slide along until it mates
with the next groove should a desirable torque level be
exceeded.
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Preferred and best mode designs and techniques are hereinafter
detailed.
DRAWINGS
The invention will now be described with reference to the
accompanying drawing
in which:
Fig. 1 is a side view of the prior art;
Fig. 2 is an isometric view of the prior art;
Fig. 3 is a side view of the current invention showing it t be a
kinematic wavy
spring washer;
Fig. 4. is an isometric view of a stack of washers of the
present invention acting as
springs physically in parallel;
Fig. 5 is an isometric view of a single washer of the present
invention;
Fig. 6. is an isometric view of a stack of washers of the
present invention acting as
springs physically in series;
Fig. 7 is an isometric view of an inner shaft;
Fig. 8 is an isometric view of an outer shaft;
Fig. 9 is an isometric exploded view of the two shafts and two
kinematic wavy
spring washers;
Fig. 10 is an isometric view of the coupled shafts shown in Fig.
9;
Fig. 11 is a side cutaway view of the coupled shafts shown in
Fig. 10;
Fig. 12 is an isometric of a rectangular kinematic wavy spring
washer;
Fig. 13 is an isometric view of a lower block of an
assembly;
Fig. 14 is an isometric of an upper block of an assembly;
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Fig. 15 is an isometric assembly of an upper and lower block
kinematically
coupled with a kinematic wavy spring washer;
Fig. 16 is an end view of an upper and lower block kinematically
coupled with a
kinematic wavy spring washer.
PREFERRED EMBODIMENT(S) OF THE INVENTION
Fig. 1 is a side view of the prior art, which shows a wavy
spring washer 5 that is
commonly used to replace a traditional coiled spring. Fig. 2 is
an isometric view of the
prior art 5 that shows the peaks 2a, 2b, and 2c and the valleys
3a, 3b, and 3c that
effectively form essentially a three dimensional sine wave.
Nominally a stack of such
washers can be assembled where the tops of the peaks mate with
the bottoms of peaks to
form a springs-in-parallel stack that has a stiffness about
equal to the product of the
number of washers and the spring stiffness of a washer. Such a
stack will be accurately
located with respect to each other; however, if the peaks of a
washer contact the bottoms
of the valleys of a washer to form in effect a springs-in-series
stack of washers, there are
no features to prevent the washers from displacing with respect
to each other and thus
lose their concentricity. In the latter case, a shaft that runs
down their center must
concentrically locate the washers, or the stack must be placed
in a bore. Either way, the
prior art washers can function only as simple spring
elements.
Fig. 3 is a side view of the current invention 9 showing it to
be a kinematic wavy
spring washer. Fig. 4. is an isometric view of a stack of
washers 9a and 9b of the present
invention acting as springs physically in parallel where the
regions 16a, 17a, and 18a
represent regions where the tops of peaks of washer 9b mate with
the bottoms of peaks of
washer 9a to in effect deterministically located one washer with
respect to the other while
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enabling them to act as springs-in-series having a spring
constant about equal to the
product of the number of washers and the spring constant of a
single washer. Notes that
there are three other such regions occurring in the valleys of
the washers, so the total
number of contact regions between the washers is six, but given
the spring nature of the
material and since they would all be stamped from the same die,
in this case the
overconstraint is not detrimental and any errors will average
elastically thereby still
effectively guaranteeing a deterministic location between the
washers.
Fig. 5 is an isometric view of a single kinematic wavy spring
washer 9 showing in
detail each of the three peak and valley regions. There are
three peaks 10b, 11b and 12b,
and three valleys 13b, 14b, and 15b. transition between peaks
and valleys occurs via the
use of section pairs 10c and 13a, and 13c and 11a, and 11c and
14a, and 14c and 12a, and
12c and 15a, and 15c and 10a. These sections are all tangent to
each other and to their
respective peaks and valleys. The effect is to create a sum of
phase-shifted sinusoids that
enable the washer 9 to act as a spring washer and also as a
quasi-kinematic coupling.
Fig. 6. is an isometric view of a stack of kinematic spring
washers 9a and 9b of
the present invention acting as springs physically in series.
Note the regions 16b, 17b,
and 18b where the peaks and valleys of the washers mate to form
a quasi-kinematic
coupling. This keeps the washers concentric, while still
allowing them to axial deflect as
spring elements. There is no danger that the washers could shift
and lose concentricity.
This greater increases the reliability of a stack of such
washers.
The bumps 10b, 11b, and 12b on the peaks of the washer are shown
as a section of a very
small angle cone, or nearly a cylinder. This shape can have
other forms including a
spherical “bump” or a canoe-like ball, as described in US Patent
5,711,647. In addition,
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the shape can be a larger angle cone, which can help to reduce
stresses along the inner
diameter of the washer.
In a conventional wavy washer the amplitude of the wave is
largely similar
between the outside and inside diameters (OD to ID). A
consequence is that with a
smaller circumference, the metal at the ID has to flex through a
larger angle and about a
smaller radius than that of the OD. It is thus being worked more
aggressively, and will
become the weak link at the point of failure. This negative
effect can be mitigated both
by increasing the effective length of the ID circumference and
thinning the metal at this
zone. To increase the length (without increasing the overall
amplitude or ID) a secondary
wave can be overlaid such that it appears as a section of a cone
extending from maximum
amplitude at the ID to minimum at the OD. When this conical
section is pressed in from a
blank it also thins the metal (as it is spread over a larger
surface area). This has a
cooperating helpful effect in further reducing bending stresses.
The conical section need
not be too extreme to compensate for the varying stresses
between OD and ID. A washer
given this treatment will have no weak link and will thus make
better use of its material.
This conical section can be combined with the desirable locating
features, which
are another object of this invention. The locating peaks and
troughs can increase in
amplitude between OD and ID such that in one extreme they have
zero amplitude at the
OD and extend uniformly towards their maximum amplitude at the
ID.
While the invention has been described with reference to
circular washers with
three waves, other shapes and styles are possible and may indeed
be desirable for some
applications. For example, if the washer has only two waves it
can have greater
amplitude for the same metal stress when flattened. This enables
a bigger compression
ratio. It does not however locate kinematically and can only be
stacked as a pair before
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the stack becomes unstable. However, to locate a two-wave washer
one could use a
socket and dimple style, as it locates about 2 axes rather than
just one. Of course this style
would not be universally useful as it is over-constrained and
hence less kinematic. If the
washer has four or more waves it's compression ratio will
decrease and it's quasi -
kinematic location becomes over-constrained; however they may be
benefits for washers
with large diameters compared to their thickness and/or width in
generating a greater
number of contact zones.
Kinematic stacking washers need to have at least 3 upper and 3
lower contact
zones with two-each contact points or lines (for a total of six
contact points or lines). This
can be accommodated with shapes other than round. One other
style that particularly
lends itself to this objective is a hexagonal washer. In this
embodiment the waves would
be principally carried in the side length defined by the inner
boundary hexagon, while the
extensions afforded by the longer sides of the outer boundary
hexagon can be deformed
into the stacking location features.
Fig. 7 is an isometric view of an inner shaft 30 with a base 38
and surfaces 32 and
34 which each have peaks 31c, 31b, 31a and 33c, 33b (and not
showable because of the
isometric view, but would otherwise be 33a) respectively.
Threaded hole 35 in the top
plate 32 will allow for the axial preloading of an outer shaft.
Fig. 8 is an isometric view
of an outer shaft 40 with surfaces 42 and 44 which each have
peaks 41c, 41b, 41a and
43c, 43b (and not showable because of the isometric view, but
would otherwise be 43a)
respectively. Hole 45 in the top plate 42 will allow for the
axial preloading to an inner
shaft.
Fig. 9 is an isometric exploded view of the two shafts 40 and 30
and two
kinematic wavy spring washers 19a and 19b. The kinematic wavy
spring washer 19a can
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be seen coupling to one end of the shaft 30 with the bottoms of
its bumps in its valleys
engaging the tops of bumps 33c and 33b (and 33a not shown) to
form a quasi kinematic
coupling between the washer and the plate 34. At the other end
of the shaft 30, kinematic
wavy spring washer 19b, of a smaller diameter than washer 19a,
has the bottoms of its
bumps in its valleys engaging the tops of bumps 31c 31b and 31a
to form a quasi-
kinematic coupling between the washer and the plate 32. Bumps
10b’ and 10c’ on
washer 19a will engage the bottoms of bumps 43c and 43b on shaft
40 respectively (once
again, the third bump pair cannot be seen in this view).
Similarly, bumps 10b’’ and 10c’’
on washer 19b will engage the bottoms of bumps 41c and 41b on
shaft 40 respectively
(once again, the third bump pair cannot be seen in this view,
only bump 41a)
Fig. 10 is an isometric view of the coupled shafts shown in Fig.
9 where shaft 40
is fitted over shaft 30 and the kinematic coupling regions 43b
and 43c (43a cannot be
seen in this view) couples the washer 19a kinematically to plate
44 attached to shaft 40,
and the kinematic coupling regions 33c (33a and 33b cannot be
seen in this view) also
kinematically couples washer 19a to plate 34 attached to shaft
30. Plate 42 on top of
shaft 40 has bumps 41a, 41b, and 41c, the undersides of which
are kinematicaly coupled
to a washer 19b not shown in this view, but shown in cross
section in Fig. 11. Bolt 50
preloads shaft 40 to shaft 30 and prevents them from separating,
while allowing axial
compliance to occur.
Fig. 11 is a side cutaway view of the coupled shafts shown in
Fig. 10 where the
bolt 50 passes through plate 42 to engage threaded portion 35 in
plate 32 attached to inner
shaft 30. The upper portion of the figure shows kinematic
coupling regions 41a and 41b
(41c is not shown) to kinematically couple washer 19b to the
outer shaft 40, and
kinematic coupling regions 31a and 31c (31b is not shown) to
kinematically couple
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washer 19b to the inner shaft 30. At the bottom of the figure,
kinematic coupling regions
43c (43a and 43b are not shown) kinematically couple washer 19a
to shaft 40, and
kinematic coupling regions 33c (33a and 33b are not shown)
kinematicaly couples washer
19a to inner shaft 30. Two distinct regions of kinematic
coupling between the tops and
bottoms of the shafts are possible because of the spring nature
of the washers 19a and
19b; however, as a pair, they will rigidly couple the two shafts
together, while allowing
some axial compliance. This greatly eases the assembly of the
two shafts, and increases
the accuracy and ease with which they can be concentrically
assembled. Inner shaft 30
may then have torque transmitted to it by surface 38 which may
actually have an integral
motor attached to it. There are many such applications of this
type of coupling, most
notably to replace expensive splines in many types of machines.
A single such coupling
interface (one washer only) can also form an effective motor
coupling between a motor
shaft and a load.
Figs. 3-11 have shown a kinematic wavy spring washer and
assembly where the
washer has bumps on each of its peaks and valleys such that the
top of a bump can mate
with the bottom of a bump to enable the washers to
deterministically locate, as a three
groove-three bump quasi kinematic coupling, with respect to each
other to form either an
effectively series or parallel series of washers. The washers
can be used to
deterministically locate with axial compliance two components,
with similar mating
bumps on them, with respect to each other and because they are
compliant and the
coupling is quasi kinematic, two or more sets of washers can be
located along the lengths
of the components to enable one component to be rigidly
deterministically located with
respect to the other component with the exception of allowing a
degree of axial
compliance offered by the washers, and thus also being protected
against overtorquing by
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the ability of the bumps to slide out of the bottom sides,
grooves, of the mating bumps’
undersides and to slip in rotation until the next set of bumps
is engaged.
The location features have also thus far been described as
extending out in a
common direction such that for example plugs face upwards and
sockets face downwards,
thereby enabling a continuous series stack. When employed as a
coupling, it may be
advantageous to have the same locating features extending both
up and down so that any
mounting hubs against which the wavy washers might bare could
also be identical. Such a
washer can stack with any number of the previously described
stackable washers, but
must be at the appropriate end of the stack. It cannot stack
with it's own kind.
One embodiment of a coupling working on this principle would
feature identical
mounting hubs suitably clamped to both motor and load shafts
such that one or more
washers can be trapped in between. If a single washer is used
the coupling can support
three degrees of freedom. If two or more are used it can support
all five. The assembly is
preloaded on installation as determined by the axial offset of
the two mounting hubs.
The hubs can include features to assist in retaining the
washer(s) during installation and
preventing them from becoming irrevocably displaced. Such a
feature could be a
cylindrical wall loosely surrounding the washer, but such as not
to interfere during use
when the washer(s) locates kinematically against each hub.
The kinematic wavy spring washer also need not be round as shown
in Fig. 12
where washer 200 is rectangular with three downward facing
crowned cone protrusions
202a, 202b, and 202c on flexing arms 204a, 204b, and 204c. Three
upward facing
crowned cone protrusions 201a, 201b, and 201c on flexing arms
203a, 203b, and 203c.
Wavy kinematic spring 200 would fit on lower black 300 shown in
Fig. 13, which has
vee-grooves 301, 302, and 303 into which crowned cones 202a,
202b, and 202c would
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make contact at 2 points each for a total of six points of
kinematic contact. Lower block
300 also has a riser 305 onto which another part’s vertical
position would be established
as the kinematic wave washer 200 flexes. The upper block 400 to
be kinematically
coupled to the lower block 300 is shown in Fig. 14 which has
vee-grooves 401, 402, and
403 into which crowned cones 201a, 201b, and 201c would make
contact at 2 points each
for a total of six points of kinematic contact.
The kinematic assembly of upper block 400 to lower block 300 by
the action of
kinematic wavy spring washer 200 is shown in Figs. 15 and 16.
Note that of the blocks
were to be compressed, the underside of upper block 400 would
contact the top of riser
305 to limit its vertical travel, or actually provide a rigid
interface should the two blocks
be rigidly coupled. In this manner, the kinematic wavy spring
washer works like a two-
sided version of the flexural kinematic coupling described by US
Patent #5,678, 944. An
example of applications requiring this configuration is the easy
or automatic location and
changing of electrical contacts or other tooling.
An example of the use of this type of arrangement is an
electrical contactor as
used in Automated Test Equipment (ATE), and a Handler Interface
Board (HIB) on a
handling machine that presents parts to be tested to the ATE. In
this application, the
contactors frequently become clogged with solder as they contact
the solder leads of
devices under test (DUTs), and they need to be rapidly
changed.
Another example of the use of this type of arrangement would be
the coupling of a
washing machine drum to the post that extends from the
transmission. It is needed to
blindly couple the two with high backlash-free torque capacity
to minimize noise.
Another application is the use of a single or double kinematic
wavy spring
arrangement to couple the shaft of an electric motor to another
shaft, such as a ballscrew
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shaft. In the even of overtorquing, the washer can compress by
the action of the bumps
sliding out of their mating grooves, yet then they re-engage
with the next set of grooves as
the torque level drops.
Further modifications of the invention will also occur to
persons skilled in the art,
and all such are deemed to fall within the spirit and scope of
the invention as defined by
the appended claims.
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What is claimed is:
1. A wavy spring washer with integral bumps and grooves
superimposed on the tops
and bottoms of the waves respectively to enable the washers to
locate with respect
to each other deterministically to provide more accurate
centering and to be less
likely to slip off of each other when stacked, and such that the
integral bumps and
grooves enable the spring washers to mate with corresponding
bumps or grooves
on other components to deterministically, that is kinematically,
locate them, and
to also enable torques and forces to be transmitted between
components, so the
washers act as a spring coupling between components.
2. The system as claimed in claim 1 where two components are to
be kinematically
located with respect to each other with compliance between
them.
3. The system as claimed in claim 1 where two components are to
be kinematically
located with respect to each other with space between them, and
then squeezed
together, thereby compressing the kinematic wavy spring washer,
so as to achieve
surface contact between the components.
4. A wavy spring washer as claimed in claim 1 with a secondary
wave superimposed
on its inner diameter region to reduce circumferential stresses
when the washer is
compressed.
5. A system as claimed in claim 1 where one component is a
shaft, and the other
component is a motor shaft so as to flexibly kinematically
couple the motor shaft
to the shaft with a high degree of torsional stiffness.
6. The system as claimed in claim 5 where the flexibility of the
kinematic wavy
spring washer enables the bumps and grooves to slide out from
each other in the
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event of overtorquing, and then mate back together again as the
shafts spin
relative to each other.
7. A system to couple two components with large aspect ratios
where the bases of
the objects have flanges with bumps and grooves that mate
correspondingly with
grooves and bumps on a wavy spring washer, and the tops of the
objects have
surfaces with bumps and grooves that mate correspondingly with
grooves and
bumps on a second wavy spring washer, such that the top and
bottoms of the
components are kinematically located with respect to each other
and yet are not
over constrained due to the flexing action of the wavy spring
washer, thereby
allowing the long objects to be kinematically flexibly
coupled.
8. The systems as claimed in claim 7 where the components are
the drum of a
washing machine and the transmission post of a washing
machine.
9. The system as claimed in claim 7 where the components are an
electrical
contactor as used in Automated Test Equipment, and a Handler
Interface Board.
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Abstract
A kinematic wavy spring washer and assembly where the washer has
bumps on
each of its peaks and valleys such that the top of a bump can
mate with the bottom of a
bump to enable the washers to deterministically locate, as a
three groove-three bump
quasi kinematic coupling, with respect to each other to form
either an effectively series or
parallel series of washers. The washers can be used to
deterministically locate with axial
compliance two components, with similar mating bumps on them,
with respect to each
other and because they are compliant and the coupling is quasi
kinematic, two or more
sets of washers can be located along the lengths of the
components to enable one
component to be rigidly deterministically located with respect
to the other component
with the exception of allowing a degree of axial compliance
offered by the washers, and
thus also being protected against overtorquing by the ability of
the bumps to slide out of
the bottom sides, grooves, of the mating bumps’ undersides and
to slip in rotation until
the next set of bumps is engaged.
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# 1412 4/6/2001
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Peter Bailey, Alexander Slocum, Scott Ziegenhagen Teradyne case
# 1412 4/6/2001
-
Peter Bailey, Alexander Slocum, Scott Ziegenhagen Teradyne case
# 1412 4/6/2001
-
Peter Bailey, Alexander Slocum, Scott Ziegenhagen Teradyne case
# 1412 4/6/2001
-
Peter Bailey, Alexander Slocum, Scott Ziegenhagen Teradyne case
# 1412 4/6/2001
-
Peter Bailey, Alexander Slocum, Scott Ziegenhagen Teradyne case
# 1412 4/6/2001
-
Peter Bailey, Alexander Slocum, Scott Ziegenhagen Teradyne case
# 1412 4/6/2001
-
Peter Bailey, Alexander Slocum, Scott Ziegenhagen Teradyne case
# 1412 4/6/2001