Breakaway Threaded Fastener Structure Without Special Tools

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing breakaway threaded fasteners are overly complex, costly, difficult to use, and require special tools, leading to increased failure modes.

Innovation Solution

A breakaway threaded fastener design featuring a stud, pin, and cap with specific thread configurations and material properties that allow for easy assembly and use, breaking under tension or torsion without the need for additional tools, ensuring a simple and efficient connection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If prior art breakaway threaded fasteners are designed with complex structures to achieve breakaway functionality, then the breakaway function is achieved, but the manufacturing cost increases, difficulty of use increases, and failure modes increase

Engineering Contradiction:

Improvebreakaway functionVSAvoidfastener structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The fastener is divided into two main segments: a stud portion and a cap portion. The stud includes a shank and external threads, while the cap includes internal threads and a breakaway section. This segmentation allows the breakaway functionality to be achieved through a simple structural division rather than complex mechanisms.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The breakaway functionality is extracted as a separate feature - the breakaway section is a distinct portion of the cap that is designed to fail under specific conditions. This extraction simplifies the overall design by isolating the breakaway function to a specific structural element rather than distributing complexity throughout the entire fastener.

Inventive Principle:

Principle #2Taking out (Extraction)

2Reliability

If prior art breakaway threaded fasteners use complex structures to ensure breakaway, then the breakaway function is achieved, but the manufacturing cost increases

Engineering Contradiction:

Improvebreakaway functionVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The breakaway section is designed with specific dimensional parameters - a reduced cross-sectional area compared to the shank. This parameter change creates a predetermined failure point that achieves the breakaway function through simple geometric design rather than complex manufacturing processes or special materials.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If prior art breakaway threaded fasteners use complex structures to achieve breakaway, then the breakaway function is achieved, but the difficulty of use increases and special tools are required

Engineering Contradiction:

Improvebreakaway functionVSAvoiddifficulty of use

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The fastener is designed to self-breakaway under excessive torque conditions without requiring any special tools or additional operations. The breakaway section automatically fails when the applied torque exceeds the strength of the reduced cross-sectional area, providing a self-regulating mechanism that simplifies usage.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The breakaway section is designed as a disposable element that is intended to fail under specific conditions. This approach simplifies the overall fastener design by using a simple, replaceable component rather than a complex, reusable mechanism, making the fastener easier to use and install.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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 fastener design simplifies manufacturing, assembly, and use, reducing costs and failure rates while maintaining a secure electrical and mechanical connection.

Implementation Method 1

the second end of the pin abuts the closed end of the cap

Methodology Applied

Scientific EffectCompressive force: Compression

Implementation Method 2

the cap applies a tensile force on the stud through the pin

Methodology Applied

Scientific EffectTensile force: Tension

Implementation Method 3

The cap is threadably engaged to the open end of the stud via the internal and external threads

Methodology Applied

Scientific EffectThreaded engagement: Screw

Data Source

PatentUS12546356B2Breakaway threaded fasteners and electrical connectors having such fasteners

Publication Date: 2026.02.10 HUBBELL INC

AI summary

A breakaway threaded fastener is provided. The fastener has a stud, a pin, and a cap. The stud has a hollow cavity with a closed end, an open end, a wall, and an outer surface. The outer surface has an external thread. The pin is in the hollow cavity. The pin has a first end at the closed end of the stud and a second end extending above the open end of the stud. The cap has another hollow cavity with a closed end, an open end, and an internal thread. The cap is threadably engaged to the open end of the stud via the internal and external threads so that the second end of the pin abuts the closed end of the cap.