Low-Mass Fastener Head Structure for Hex Tool Compatibility
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Solution Overview
Problem
Current hex head fasteners contain excess material in non-ideal locations, leading to inefficiencies in torque application and handling, with existing solutions failing to address the hex head's interaction with tools and material distribution effectively.
Innovation Solution
A fastener head design featuring full-height and short-height lugs positioned strategically around the axis, with a platform and hollowed-out center to minimize material usage while maintaining compatibility with existing tools, allowing for efficient torque transmission and axial load resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional hex head design is used, then compatibility with existing tools is maintained, but excess material is present in non-ideal locations leading to increased weight and reduced handling efficiency
Solution Approach 1:
The hex head is segmented into six distinct lugs arranged radially around the central axis. This segmentation allows removal of material from non-essential regions while preserving the six contact points needed for tool compatibility, directly reducing weight without sacrificing adaptability
Solution Approach 2:
Material is extracted from the center and non-essential portions of the hex head, retaining only the six lugs necessary for tool engagement. This extraction eliminates excess material in non-ideal locations while maintaining the functional geometry for existing tools
2Weight of moving object
If material is removed to reduce weight, then handling efficiency improves, but structural integrity and torque resistance may be compromised
Solution Approach 1:
Different regions of the fastener head are given different qualities: the six lugs are designed with sufficient mass and geometry to resist torque and transmit forces, while non-essential regions have material removed. This local differentiation maintains strength where needed while reducing overall weight
Solution Approach 2:
The hex head design employs asymmetric lug heights with three full-height lugs and three short-height lugs. This asymmetry optimizes the distribution of material for torque resistance while further reducing weight by eliminating unnecessary material from the short-height regions
3Ease of manufacture
If a hex head with uniform lug heights is used, then manufacturing is simplified, but material cannot be optimized for torque transmission and handling
Solution Approach 1:
The hex head features asymmetric lug heights with three full-height lugs and three short-height lugs alternating around the central axis. This asymmetric design optimizes material distribution for torque transmission and handling efficiency while remaining manufacturable through standard processes
4Weight of moving object
If only the minimum material is used for torque application, then weight is reduced, but the fastener may not adequately resist axial loading or stabilize within tooling
Solution Approach 1:
The six lugs are strategically positioned and dimensioned with appropriate local quality to perform multiple functions: resisting torque through their radial arrangement, supporting axial loads through their connection to the threaded shank, and providing stabilization surfaces for tooling. This localized material placement ensures reliability without excessive weight
Data Source
AI summary
A low mass fastener head that reduces the amount of material required in manufacturing. The fastener comprises a threaded shank having a longitudinal axis; a head attached to one end of the threaded shank, the head comprising: full-height lugs and short-height lugs positioned at approximately 0, 60, 120, 180, 240, or 300 degrees around the longitudinal axis of the threaded shank, wherein the short-height lugs are shorter than the full-height lugs. Those portions of a hex head that are not necessary for application and transmission of torque, nor necessary to resist axial loading, nor necessary to axially stabilize the fastener head within conventional driving tooling may be removed. Compatibility with existing hex head tools is maintained while improving handling of the fastener by an assembler and reducing material used in the fastener head.