Arch-Head Fastener for Gypsum Boards That Resists Pull-Out
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Solution Overview
Problem
Existing fastener elements for securing boards to frame structures tend to crack or crumble gypsum boards, and staples can be pushed out due to moisture fluctuations, compromising the integrity of the board-frame connection.
Innovation Solution
A fastener element with a pair of legs and a ductile convex arch-shaped head that penetrates both the board and frame structure, allowing the head to recess slightly below the board surface, preserving the board's structure and bearing capacity, and is retained by a tool with a concave arch-shaped abutment surface that creates the convex arch-shape during installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional staples or flat staples are used to secure boards to frame structure, then the fastening function is achieved, but the board surface is scarred or torn and the gypsum structure is cracked or crumbled
Solution Approach 1:
The head of the fastener element is given a convex arch-shape with a curved path along its entire extension, replacing conventional flat or rounded surfaces. This curved geometry allows the head to recess below the board surface while distributing compression forces along its contour, preventing gypsum cracking and surface scarring while maintaining secure fastening.
Solution Approach 2:
The fastener element head is designed with specific geometric parameters including a convex arch-shape with controlled curvature radius and height. The head thickness varies along its length, being thickest at the apex of the arch and tapering toward the legs, creating optimal stress distribution that preserves board integrity while ensuring reliable fastening.
2Productivity
If projections are added to the driving element to concentrate driving force, then the fastening efficiency is improved, but the upper parts of the legs are forced towards each other causing gypsum to crack and crumble
Solution Approach 1:
The driving element features a concave arch-shaped abutment surface with a curved path that complements the convex arch-shape of the fastener head. This curved contact surface distributes the driving force along the head's contour rather than concentrating it at discrete projection points, achieving efficient fastening without forcing the legs together and cracking the gypsum.
Solution Approach 2:
Instead of adding projections to the driving element that force the legs together, the solution inverts the approach by using a concave arch-shaped abutment surface that distributes force along the head's curved path. This inverted geometry achieves force concentration where needed (at the head-apex) while avoiding harmful leg convergence.
3Reliability
If conventional staples are used, then the fastening function is achieved, but the staples are pushed out due to moisture fluctuations in the frame structure
Solution Approach 1:
The convex arch-shape of the fastener element head creates a mechanically interlocking configuration with the concave arch-shaped abutment surface of the driving element. This curved geometry prevents the fastener from being pushed out along its original insertion path, as the arch-shape resists axial displacement and maintains stable retention despite moisture-induced dimensional changes in the wooden frame structure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively secures boards to frame structures, maintaining the board's integrity and resisting pull-out forces, while preserving the board's structural and bearing capabilities, even under moisture changes.
Implementation Method 1
the head of the fastener element has a straight extension, which during a fastening operation, for driving of the fastener element into the board and frame structure, is ductile to a convex arch-shape
Data Source
AI summary
The disclosure relates to a fastener element for fixating boards to a frame structure, the fastener element comprises: a pair of legs each comprising a first end and a second end, and a head, which extends between the legs and which is connected to the first end of each leg, wherein the head of the fastener element has a straight extension and is ductile to a convex arch-shape which during a fastening operation, for driving of the fastener element into the board and frame structure, is ductile to a convex arch-shape; wherein the convex arch-shape of the head has a curved path along the entire extension of the head, and wherein a distance (d1-dn) between any point (P1-Pn) on the head and the second end of each leg increases during the fastening operation. The disclosure further relates to a tool for driving a fastener element into boards and a frame structure. The disclosure further relates to a fastener system for fastening boards to a frame structure.