Self-Drilling Fastener Geometry for Insulation Board Anchoring
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Solution Overview
Problem
Existing fastening elements for attaching components to thermal insulation composite systems are cumbersome and time-consuming, requiring separate dowels, additional drilling, and complex production processes, and often fail to provide a secure hold due to inadequate thread geometry and material limitations.
Innovation Solution
A one-piece metal fastening element with a self-tapping, steep thread and drill head, featuring a large thread-to-shank diameter ratio, allowing for direct user application without pre-drilled holes and ensuring secure attachment to insulation boards through a self-drilling and self-tapping mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate plastic dowels and screws are used to attach components to thermal insulation composite systems, then the component can be securely fastened, but the installation process becomes cumbersome and time-consuming requiring multiple steps including pre-insertion of dowels, additional drilling, and separate screwing operations
Solution Approach 1:
The patent combines the dowel and screw into a single integrated fastening element. The one-piece construction merges the insertion function (dowel) and the fastening function (screw) into one component, eliminating the need for separate insertion and fastening steps. This directly reduces installation time while maintaining secure fastening through the unified structure that integrates both functions.
Solution Approach 2:
The fastening element performs multiple functions simultaneously: it acts as both an insertion tool (drill head for creating holes) and a fastening mechanism (self-tapping thread for securing components). This multi-functionality eliminates the need for separate tools and steps, reducing installation complexity and time while ensuring reliable attachment to thermal insulation composite systems.
2Ease of manufacture
If conventional screws with standard thread geometry are used, then the fastening element can be easily manufactured, but the holding force in the insulating material is insufficient due to inadequate thread surface area
Solution Approach 1:
The patent modifies the thread geometry parameters to optimize holding force. The self-tapping thread features an increased outer diameter relative to the core diameter, creating a larger thread surface area that engages more extensively with the insulating material. This parameter change enhances the mechanical interlocking and frictional resistance, significantly improving holding force while remaining manufacturable through standard metal forming processes.
3Manufacturing precision
If the fastening element requires pre-drilled holes in the component, then the hole geometry can be precisely controlled, but the installation process becomes more complex and time-consuming
Solution Approach 1:
The fastening element incorporates an integrated drill head that performs the hole-making function as part of the installation process itself. The drill head automatically creates the necessary hole in the component during fastening installation, eliminating the need for separate pre-drilling operations. This self-service approach maintains adequate hole geometry control while significantly simplifying the overall installation process.
Solution Approach 2:
The drill head is pre-integrated onto the fastening element, preparing the hole-making capability in advance. This preliminary integration of the drilling function ensures that the correct hole geometry is created automatically during installation, eliminating the need for separate precision drilling operations and simplifying the installation process.
4Ease of manufacture
If plastic dowels are used for fastening, then the production process is simplified, but the fastening element cannot provide adequate anchoring in hard insulating materials due to material strength limitations
Solution Approach 1:
The patent employs a composite structure combining different materials for different functions: a metal fastening element providing structural strength and anchoring capability, integrated with a drill head for hole creation. The metal material ensures adequate strength for anchoring in hard insulating materials while the integrated design maintains production efficiency. The self-tapping thread in metal provides the necessary mechanical strength that plastic alone cannot achieve.
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
Enables easy and secure fastening of components to insulation boards with a single tool, reducing assembly time and complexity, while providing a strong hold due to the large thread surface area and self-tapping capability, suitable for various components and insulation types.
Implementation Method 1
the shank has a self-tapping thread which extends helically along at least part of the shank circumference to the head
Implementation Method 2
the end of the shank opposite the head carries a drill head with two or more cutting edges, which protrudes radially in relation to the shank
Implementation Method 3
a sealing ring arranged on the head side on the shank for sealing a hole in the accommodating fastening element component
Data Source
Figure 1
AI summary
Fastening element (1) with a head (2), a shank (3) and a sealing ring (5) arranged on the head side on the shank (3) for sealing a hole in the component accommodating the fastening element (1). The head (2) has a gripping contour (7) and the shank (3) has a self-tapping thread (6) which extends helically along at least part of the circumference of the shank to the head (2). The ratio of the outside diameter (D1max, D1min) of the thread (6) to the core diameter (D2) of the shank (3) is at least 1.8. The end of the shank (3) opposite the head (2) carries a drill head (10) with two or more cutting edges, which protrudes radially in relation to the shank (3), so that a hole can be made in the component or an existing one can be drilled out if necessary. without the need for another drilling tool. Finally, the head (2), shank (3), its thread (6) and the drill head (10) are made of metal in one piece, so that no additional dowel is required.