Self-Drilling Expansion Fastener Integrally Formed From Sheet Metal
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Solution Overview
Problem
Conventional expansion fasteners require multiple steps for installation and have high manufacturing costs due to welding and the need for pre-drilled holes, making them time-consuming and labor-intensive.
Innovation Solution
A self-drilling expansion fastener is developed, integrally formed from sheet metal through punching and stamping, featuring an expansion structure with internal threads and a drill structure that can self-drill holes, allowing for one-step installation and reduced production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional expansion fastener uses welding to connect nut and bottom cover to barrel body, then manufacturing cost increases and production time increases, but structural strength is maintained
Solution Approach 1:
The patent integrates the nut, bottom cover, and barrel body into a single integrally formed component made from sheet metal material. This eliminates the need for welding connections between separate parts, reducing manufacturing cost and production time while maintaining structural integrity through the integral design.
Solution Approach 2:
The patent removes the welding process from the manufacturing sequence by designing a component that can be formed directly from sheet metal through punching and stamping operations. This extraction of the welding step eliminates associated costs and time requirements while achieving the same functional result through integral forming.
2Productivity
If conventional expansion fastener requires pre-drilled hole and hammer installation, then installation time increases and labor cost increases, but secure attachment is achieved
Solution Approach 1:
The patent combines the drilling function and fastening function into a single tool. The drill structure with cutting edges enables the expansion fastener to drill its own hole while being installed, eliminating the need for separate drilling and fastening operations. This merging of functions reduces installation steps and improves productivity.
Solution Approach 2:
The expansion fastener performs the drilling operation itself during installation through its integrated drill structure. The tool is self-sufficient, creating its own installation path without requiring pre-drilled holes or separate drilling equipment, thereby simplifying the installation process and reducing labor requirements.
3Device complexity
If conventional expansion fastener uses separate components, then manufacturing flexibility is maintained, but assembly time increases and production complexity increases
Solution Approach 1:
The patent consolidates multiple separate components (nut, bottom cover, barrel body) into a single integrally formed component. This reduction in component count simplifies the assembly process, eliminates assembly time, and increases production efficiency while the integral design maintains the necessary structural functions.
Solution Approach 2:
The single integrally formed component performs multiple functions that previously required separate parts: the barrel body provides expansion functionality, the integrated nut provides threading and fastening, and the integrated bottom cover provides closure. This multi-functionality within a single component reduces assembly complexity and improves production efficiency.
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 self-drilling expansion fastener simplifies the installation process, reduces manufacturing time and costs, and effectively locks sheet workpieces with enhanced efficiency.
Implementation Method 1
a drill structure having a chip guard for covering the head of the expansion structure, and a drill forward projected from the chip guard for self-drilling a hole on the sheet workpieces
Implementation Method 2
When the barrel body 11 is subjected to a pull, the middle bars 13 are brought to expand outward and become deformed. The deformed middle bars 13 and the bolt 16 together lock an attached object 17 to a supporting object 18.
Data Source
AI summary
A self-drilling expansion fastener (20) is integrally formed of a sheet metal material for locking two or more sheet workpieces together, and includes an expansion structure (21) and a drill structure (30). The expansion structure (21) has a plurality of internal threads (24) and force-distributing bars (25). The drill structure (30) has a chip guard (31) for covering a head of the expansion structure (21), and a drill (32) forward projected from the chip guar (31) for self-drilling a hole. When an externally threaded element is screwed into the expansion structure (21) to mesh with the internal threads (24), the force-distributing bars (25) are brought to expand outward and are finally compressed into a folded state to thereby tightly lock the sheet workpieces to one another. A method of forming the self-drilling expansion fastener (20) is also disclosed.