Irregular Knurled Screw for Clean Seating in Frangible Boards
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Solution Overview
Problem
Conventional screws cause damage and uneven surfaces when driven into wood or frangible materials due to aggressive knurling, leading to chipping, splitting, or improper seating, which results in unsightly finishes and potential harm.
Innovation Solution
A screw design featuring a knurling section with intersecting grooves of varying angles and spacings that grind particles into a powder, allowing for clean seating and smooth material removal, with optional additional features like blank sections for enhanced powder discharge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional aggressive knurling is used to bore the hole and remove particles, then particle removal capability is improved, but material damage (chipping, splitting) increases
Solution Approach 1:
The knurling pattern parameters are changed from conventional aggressive designs to irregular patterns with varying groove depths, widths, and angles. This transforms the cutting action from aggressive removal to controlled grinding, reducing material damage while maintaining particle removal effectiveness
Solution Approach 2:
The knurling grooves are designed with asymmetric and irregular characteristics rather than uniform symmetric patterns. The varying groove dimensions and orientations create a grinding action that effectively breaks down particles without causing splintering or chipping of the surrounding material
2Ease of operation
If conventional knurling is used to bore the hole, then insertion ease is improved, but surface finish quality deteriorates
Solution Approach 1:
The knurling groove parameters (depth, width, angle, spacing) are optimized to create a grinding action that produces a smooth surface finish. The irregular pattern ensures uniform material removal without creating tool marks or surface irregularities, enabling clean seating of the screw head
3Productivity
If aggressive knurling threads are used to carry particles out, then particle discharge efficiency is improved, but board damage (chipping, splintering) increases
Solution Approach 1:
The knurling thread parameters are modified to create irregular patterns with varying groove characteristics. This transforms the particle discharge mechanism from aggressive scraping to controlled grinding and lifting, efficiently removing particles while minimizing damage to the board edges and surface
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 screw effectively grinds particles into a powder, preventing damage and ensuring a smooth, flat surface finish by efficiently removing material while seating cleanly, suitable for both wood and frangible materials.
Implementation Method 1
the knurling section is configured to grind particles of board material into a powder as the screw is driven into the board
Data Source
AI summary
A screw includes a shank having a head, a point, a threaded section and a knurling section. The threaded section is located between the head and the point. The knurling section is located between the head and the threaded section. The knurling section includes a first set of grooves consisting of a plurality of first grooves and a second set of grooves consisting of a plurality of second grooves. The plurality of first grooves extends in a first angle relative to an axis of the shank. The plurality of second grooves extends in a second angle relative to the axis of the shank not parallel to the first angle. The first angle is equal to or larger than 0 degrees. The first grooves have unequal spacing. The first grooves intersect with the second grooves to form a plurality of intersecting zones with peaks and ridges of different sizes and shapes.