Panel Fastener Shank Geometry for Uniform Depth and Holding Power
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Solution Overview
Problem
Existing ceiling and wall panel fastening systems face challenges in securely attaching easily compressed panels without causing deformation, as conventional screws can penetrate too far and result in insufficient holding power and uneven panel surfaces.
Innovation Solution
A panel fastener with a large washer-type head and a central shank, featuring high-low threads and a constant shank diameter, which allows for precise depth control and secure attachment without damaging the panel, ensuring uniform fastening and preventing screw heads from being pulled through the panel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional screws are used to fasten ceiling panels, then the panels can be attached to the supporting structure, but the screws can penetrate too far causing permanent deformation of the panel and insufficient holding power
Solution Approach 1:
The patent changes the geometric parameters of the fastener by providing a shank with a larger diameter than the threaded portion. This parameter change allows the shank to distribute loading over a larger area of the panel, reducing stress concentration and preventing panel deformation while maintaining secure attachment.
Solution Approach 2:
The enlarged shank acts as a cushioning element between the head and the panel material. It distributes the clamping force over a larger area before the threads engage the supporting structure, preventing excessive stress on the panel and avoiding permanent deformation.
2Manufacturing precision
If conventional screws are driven into ceiling panels, then attachment is achieved, but it is very difficult to drive screws to a uniform depth so that the heads are all at the same elevation
Solution Approach 1:
The shank with its larger diameter performs a preliminary action by contacting the panel surface first and establishing a reference depth. The transition from the shank to the smaller threaded portion creates a natural depth stop that guides the fastener to a consistent depth across multiple installations.
Solution Approach 2:
The patent introduces a parameter change in the fastener geometry where the shank diameter is larger than the thread outer diameter. This geometric parameter change creates a built-in depth control mechanism that ensures uniform penetration depth and consistent head elevation relative to the panel surface.
3Reliability
If screws are driven into easily compressed panels, then attachment is possible, but the heads can be pulled through the panel resulting in insufficient holding power
Solution Approach 1:
The patent applies parameter changes by providing a shank with a diameter larger than the threaded portion. This geometric modification increases the bearing surface area on the panel, distributing the pull-through forces over a larger area and preventing the head from being pulled through the easily compressed panel material.
Solution Approach 2:
The enlarged shank provides beforehand cushioning by creating a larger bearing surface that distributes loads before the threaded portion engages the supporting structure. This prevents excessive stress concentration that could cause the fastener head to pull through the panel.
Data Source
AI summary
A panel fastener is provided that has a head having a first surface and a second surface opposite the first surface; an engagement feature on the first surface of the head, the engagement feature being configured to be engaged by a driving tool; a shank extending from the second surface of the head; a threaded portion extending from the shank, the threaded portion having first and second helical threads arranged in an intertwined manner; the first thread extending farther radially from the central axis than does the second thread; and the shank being located between the head and the threaded portion.