Screw-less Cleanroom Wall Batten System
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Solution Overview
Problem
The use of screws to attach wall battens in cleanrooms is costly, labor-intensive, and prone to errors, generates particulates, and disrupts semiconductor manufacturing due to the need for frequent gowning and elaborate installation processes, while also posing risks to sensitive equipment from dropped screws and worn-out screw slots.
Innovation Solution
A screw-less batten system utilizing a stud with a hammerhead-nut channel and removable flanges secured by closure strips, which eliminates the need for screws by using a hammerhead-nut to engage and lock the flanges in place, preventing transverse and vertical motion of the wall panels and attachments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If screws are used to attach wall battens, then the wall structure is secure, but the installation cost increases and labor time increases
Solution Approach 1:
The patent removes screws entirely from the wall batten attachment system, extracting the harmful element (screws that generate particulates and require lengthy installation) while maintaining structural security through an alternative mechanism using extruded aluminum battens with integrated locking features
Solution Approach 2:
The wall system is divided into modular components (extruded aluminum battens, wall panels, and closure pieces) that can be quickly assembled and disassembled without screws, enabling rapid installation while maintaining structural integrity through the segmented design
2Reliability
If screws are used to attach wall battens, then the wall structure is secure, but particulate generation occurs during installation and maintenance
Solution Approach 1:
The patent extracts screws from the system entirely, eliminating the source of particulate generation that occurs when screws are driven into and removed from aluminum screw slots during installation and maintenance operations
Solution Approach 2:
The patent converts the potential harm of screw slots becoming galled and requiring replacement into a benefit by using extruded aluminum battens with integrated locking mechanisms that do not create wear surfaces, thereby eliminating particulate generation from slot wear
3Reliability
If screws are used to attach wall battens, then the wall structure is secure, but the number of parts and installation complexity increases
Solution Approach 1:
The patent merges the batten and fastening functions into a single extruded aluminum batten component with integrated locking features, eliminating the need for separate screws, washers, and other hardware, thereby reducing installation complexity while maintaining structural security
Solution Approach 2:
The extruded aluminum batten serves multiple functions simultaneously: structural support, attachment mechanism, and locking feature, replacing what would traditionally require multiple separate components including screws and mounting hardware
4Productivity
If progressive wall systems are used, then wall panels can be assembled serially, but removing a single panel requires removing all intervening panels
Solution Approach 1:
The patent uses individually attachable extruded aluminum battens for each wall panel rather than a continuous progressive system, allowing each panel to be independently secured and removed without affecting adjacent panels, thereby improving ease of repair while maintaining assembly efficiency
Data Source
AI summary
A batten system includes a stud, at least one removable flange and at least one closure strip. The at least one removable flange is secured to the stud by the closure strip without the use of a screw. The stud includes a neck opening with at least one receiving trough. The stud also includes a hammerhead-nut channel. The hammerhead-nut channel has a predetermined profile. In some embodiments, the screw-less batten system includes a hammerhead-nut.