Polygonal Counterbore Fastener for Low-Torque Clean Installation
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Solution Overview
Problem
Conventional fasteners require high torquing force for installation and often leave visible substrate fibers, limiting their effectiveness across various building materials and settings.
Innovation Solution
A multi-purpose fastener with a polygonal counterbore cutter design in the head portion, featuring a combination of polygonal cutters, helical knurling, and double threading, which reduces installation force and creates a clean counterbore with minimal fiber exposure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional fasteners are used for installation, then the fastener can secure building materials, but high torquing force is required and visible substrate fibers remain
Solution Approach 1:
The fastener head is segmented into multiple counterbore cutters (typically 3-6 cutters) arranged circumferentially around the shank axis. Each cutter is a discrete cutting element with specific geometry designed to remove substrate material. This segmentation allows the cutting action to be distributed across multiple elements rather than requiring concentrated force from a single point, reducing the overall torquing force needed during installation.
Solution Approach 2:
The counterbore cutters employ specific geometric parameters including acute cutting edge angles (typically 15-30 degrees), optimized cutter spacing, and controlled depth of engagement. These parameter changes enable the cutters to shear substrate fibers cleanly at a controlled rate, reducing resistance during insertion and minimizing the torquing force required compared to conventional fasteners that rely on blunt displacement.
2Manufacturing precision
If conventional fasteners are used for installation, then the fastener can secure building materials, but visible substrate fibers remain on the surface
Solution Approach 1:
Each counterbore cutter is designed with localized cutting edges positioned at specific angles and depths to address the local substrate material characteristics. The cutters create a clean counterbore cavity that removes fibers uniformly around the fastener insertion point, preventing fiber protrusion above the substrate surface. This local quality control ensures consistent clean appearance across different installation locations.
Solution Approach 2:
The counterbore cutters perform preliminary cutting action before the fastener threads engage the substrate. By pre-removing material and creating a clean counterbore cavity ahead of the threading action, the system prevents fiber disruption and protrusion that would otherwise occur during thread insertion. This preliminary material removal ensures a clean surface finish is achieved before the fastening action commences.
Data Source
AI summary
A fastener for use with building materials has an upper head with an underside with a plurality of cutters. The cutters are circumferentially spaced from each other with a respective cutout therebetween. The cutters or cutouts or both can have an irregular polygonal cross sectional shape. A lower shank extends from the head to a distal tip and includes threading on at least a portion thereof.