Drywall Screw Structure to Prevent Plasterboard Surface Bulging
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Solution Overview
Problem
Existing drywall screws often cause the surface of plasterboards to bulge when fastened to metal supports due to displacement of material, resulting in an uneven and unsightly surface.
Innovation Solution
A drywall screw design featuring an expanding element that creates a larger hole in the plasterboard, which breaks off upon impact with the metal support, accompanied by an unthreaded underhead section to accommodate displaced material, and a cutting element to manage the plasterboard border, reducing bulging risk.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the head displaces material during fastening, then the fastening function is achieved, but the surface becomes bulged and uneven
Solution Approach 1:
The invention extracts the harmful displaced material from the surface area by creating a larger borehole than the head diameter. The threadless lower head section with receiving volume V2 captures and removes the displaced material from the critical surface zone, preventing bulging while maintaining fastening reliability.
Solution Approach 2:
The displaced material that would normally cause surface bulging is captured in the receiving volume V2 of the threadless lower head section. This material is effectively discarded from the surface zone and contained in a non-critical area, transforming a harmful effect into a contained byproduct that does not affect surface smoothness.
2Shape
If a larger borehole is created to accommodate displaced material, then surface bulging is reduced, but the screw structure becomes more complex
Solution Approach 1:
The invention merges the head function with an integrated threadless lower head section that includes the receiving volume V2. This combined structure performs multiple functions: anchoring the screw, capturing displaced material, and providing a transition zone, thereby reducing overall device complexity compared to separate components.
Solution Approach 2:
The threadless lower head section serves multiple functions simultaneously: it acts as a structural transition between head and threaded section, provides a receiving volume for displaced material, and defines the borehole diameter relationship. This multi-functionality reduces the need for additional components to address surface bulging.
Data Source
Figure 1~2
AI summary
The invention relates to a dry-construction screw (1) for fastening a plasterboard panel to a metal support, comprising a head (2), a tip portion (3) and an elongate shaft (4), wherein the tip portion is joined to the shaft, wherein the dry-construction screw comprises an enlarging element (5) which is suitable for enlarging the first drilled hole in the plasterboard panel up to a first drilled-hole diameter t and for breaking off when it strikes the metal support, wherein an insertion volume V1 of the head exceeds the first drilled-hole diameter t, wherein the shaft comprises a thread-free under-head portion, the receiving volume V2 of which is less than the first drilled-hole diameter t, which volume is at least 80% of the insertion volume V1.