Washer-Head Panel Fastener for Uniform Depth and Holding Power
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Solution Overview
Problem
Existing fastening systems for easily compressed ceiling or wall panels often result in panel deformation and insufficient holding power due to the difficulty in driving screws to a uniform depth without damaging the panel.
Innovation Solution
A panel fastener with a large washer-type head and a central shank, featuring high-low threads, which allows for secure attachment of panels to a structure without deforming them, by controlling the depth of screw insertion and distributing force evenly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional screws are used to fasten easily compressed panels, then the panels can be attached to the supporting structure, but the panels are easily deformed and the holding power is insufficient
Solution Approach 1:
A washer is introduced as an intermediary element between the screw head and the panel surface. The washer distributes the clamping force over a larger area, preventing local deformation of the easily compressed panel while maintaining secure attachment to the supporting structure.
Solution Approach 2:
The screw design incorporates a larger head diameter and optimized thread parameters. The increased head size provides greater bearing surface area to reduce pressure on the panel, while modified thread geometry enhances holding power in the supporting structure without requiring excessive insertion depth.
2Manufacturing precision
If conventional screws are driven into panels, then attachment is achieved, but uniform depth control is difficult and screw heads end up at different elevations
Solution Approach 1:
The screw head incorporates a pre-configured bearing surface with a specified thickness that establishes the final elevation position before the panel is fully compressed. This preliminary geometric constraint ensures that all screw heads terminate at a uniform elevation relative to the panel outer face, eliminating the need for precise depth control during driving.
3Strength
If screws are driven too far into easily compressed panels, then attachment strength increases, but permanent deformation occurs and holding power decreases
Solution Approach 1:
The washer acts as a mediator that decouples the relationship between screw insertion depth and panel compression. By providing a distributed bearing surface, the washer allows the screw to achieve full attachment strength in the supporting structure without transmitting excessive point loads to the panel, thereby preventing permanent deformation.
Solution Approach 2:
The washer provides beforehand cushioning by absorbing and distributing the clamping forces before they reach the panel surface. This protective layer prevents the screw from directly compressing the easily deformed panel material, maintaining panel integrity while still achieving secure fastening.
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.