SHEET METAL SCREW

Abstract

A sheet metal screw includes one or more of a tapered self-drilling tip, an asymmetric thread angle and/or a trilobular thread edge profile.

Claims

1. A sheet metal screw, comprising: a head end, an entry tip end and shank running between the head end and the entry tip end, wherein the shank includes a first portion that runs from proximate the head end and toward the entry tip end and includes a self-tapping thread, and a second portion that runs from the first portion to the entry tip end and forms a self-drilling tip that is unthreaded, wherein the shank includes at least one flute on the self-drilling tip that runs from the entry tip end toward the first portion of the shank, wherein a base diameter of the shank along the first portion is substantially uniform, and wherein a base diameter of the shank along the second portion reduces in size when moving from the first portion toward the entry tip end to such that the self-drilling tip is defined as a tapered self-drilling tip.

2. The sheet metal screw of claim 1 wherein a taper angle of the tapered self-drilling tip is between about five degrees and about twenty-seven degrees.

3. The sheet metal screw of claim 2 wherein the self-tapping thread is one of a single lead thread, a double lead thread or a triple lead thread.

4. The sheet metal screw of claim 2 wherein an entry tip segment of the tapered self-drilling tip is defined by an entry taper, and the entry taper is between about one-hundred five and about one-hundred fifteen degrees.

5. The sheet metal screw of claim 4 wherein an axial length of the entry tip segment is no more than twenty percent of an axial length of the tapered self-drilling tip.

6. The sheet metal screw of claim 1 wherein the self-tapping thread includes a symmetric thread angle of between about thirty and about forty-eight degrees, and a trilobular thread edge profile in end view.

7. The sheet metal screw of claim 1 wherein the self-tapping thread includes a symmetric thread angle of between about thirty and about forty-eight degrees, and a circular thread edge profile in end view.

8. The sheet metal screw of claim 1 wherein the self-tapping thread includes an asymmetric thread angle.

9. The sheet metal screw of claim 8 wherein the self-tapping thread includes a leading flank angle of between about twenty and about twenty-five degrees, and a trailing flank angle of between about ten and about fifteen degrees.

10. The sheet metal screw of claim 8 wherein the self-tapping thread includes a trilobular thread edge profile in end view.

11. The sheet metal screw of claim 8 wherein the self-tapping thread includes a circular thread edge profile in end view.

12. The sheet metal screw of claim 8 wherein the self-tapping thread includes a leading flank angle of between about twenty and about twenty-five degrees, and a trailing flank angle of between about ten and about fifteen degrees, and a trilobular thread edge profile in end view, facilitating sheet metal penetration.

13. A sheet metal crew, comprising: a head end, an entry tip end and shank running between the head end and the entry tip end, wherein the shank includes a first portion that runs from proximate the head end and toward the entry tip end and includes a self-tapping thread, and a second portion that runs from the first portion toward the entry tip end and forms a self-drilling tip that is unthreaded, wherein the shank includes at least one flute on the self-drilling tip that runs from the entry tip end toward the first portion of the shank, wherein a base diameter of the shank along the first portion is substantially uniform and a base diameter of the shank along the second portion is substantially uniform, and wherein the self-tapping thread includes a trilobular thread edge profile in end view.

14. The sheet metal screw of claim 13 wherein (i) the base diameter along the second portion is substantially the same as the base diameter along the first portion or (ii) the base diameter along the second portion is smaller than the base diameter along the first portion.

15. The sheet metal screw of claim 13 wherein the self-tapping thread includes a symmetric thread angle of between about thirty and about forty-eight degrees.

16. The sheet metal screw of claim 13 wherein the self-tapping thread includes an asymmetric thread angle.

17. The sheet metal screw of claim 16 wherein the self-tapping thread includes a leading flank angle of between about twenty and about twenty-five degrees, and a trailing flank angle of between about ten and about fifteen degrees.

18. A sheet metal screw, comprising: a head end, a self-piercing tip end and a shank running between the head end and the self-piercing tip end, wherein the shank includes a primary portion running from proximate the head end toward the self-piercing tip end and a tapered portion running from the primary portion toward the self-piercing tip end, with a self-tapping thread running from proximate to the head end and along both the primary portion and the tapered portion toward the self-piercing tip end, wherein the self-tapping thread has an asymmetric thread angle and a trilobular thread edge profile in end view.

19. The sheet metal screw of claim 18 wherein the self-tapping thread includes a leading flank angle of between about twenty and about twenty-five degrees, and a trailing flank angle of between about ten and about fifteen degrees.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] FIGS. 1-4 show prior art screws;

[0011] FIG. 5 shows a side elevation of one embodiment of a sheet metal screw;

[0012] FIG. 6 shows one embodiment of a thread angle for the screw of FIG. 5;

[0013] FIG. 7 shows one embodiment of a thread edge profile end view for the screw of FIG. 5;

[0014] FIG. 8 shows another embodiment of a thread angle for the screw of FIG. 5;

[0015] FIG. 9 shows a side elevation of one embodiment of a sheet metal screw;

[0016] FIG. 10 shows one embodiment of a thread angle for the screw of FIG. 9;

[0017] FIG. 11 shows one embodiment of a thread edge profile end view for the screw of FIG. 9;

[0018] FIG. 12 shows another embodiment of a thread angle for the screw of FIG. 9;

[0019] FIG. 13 shows a side elevation of one embodiment of a sheet metal screw;

[0020] FIG. 14 shows a thread angle for the screw of FIG. 13;

[0021] FIG. 15 shows a thread edge profile end view for the screw of FIG. 13; and

[0022] FIGS. 16 and 17 show another embodiment of a sheet metal screw.

DETAILED DESCRIPTION

[0023] Referring to FIG. 5, one embodiment of a sheet metal screw 10 is shown. The screw includes a head end 12, a shank 14 (also commonly referred to as the elongated body or elongated core of the screw) and an entry tip end 16. The head end 12 includes a tool engaging part 18 (e.g., in the form of a drive receiving recess) and is located at one end of the shank 14, and the entry tip end 16 is located at an opposite end of the shank 14. The shank 14 includes a first portion 14a that runs from proximate the head toward end 16 and includes a helically extending self-tapping thread 20, and a second portion 14b that runs from the first portion to the entry tip end and forms a self-drilling tip 22 that is unthreaded. The shank includes at least one flute 24 (typically two diametrically opposed flutes) on the self-drilling tip (e.g., as may be created by cutting or forming), where the flute runs from the entry tip end 16 toward the first portion 14a of the shank. The flute(s) are recessed portions of the shank that form cutting edges on the self-drilling tip. A base diameter D1 of the shank along the first portion 14a is substantially uniform. However, a base diameter (D2a, D2b) of the shank along the secondary portion 14b reduces in size, as shown, when moving from the first portion toward the entry tip (e.g., D2a is greater than D2b) to define a tapered self-drilling tip, which also results in a taper in the cutting edge(s) formed by the flute(s). The term base diameter as used herein refers to the projected shank in end view (not taking into account any flutes that may be included in the shank).

[0024] A taper angle of the tapered self-drilling tip may be between about five degrees and about twenty-seven degrees (e.g., such as between 10 and 15 degrees). As shown, an entry tip segment 22a of the self-drilling tip 22 is defined by an entry taper, and an angle of the entry taper is larger (e.g., three or more times larger than the taper angle ), such as between about one-hundred five and about one-hundred fifteen degrees. An axial length L22a of the entry tip segment may be no more than twenty percent (e.g., no more than about fifteen percent) of an overall axial length L22b of the self-drilling tip. An advantage of a tapered self-drilling tip as described is that it facilitates quicker sheet metal penetration with a smaller hole to provide tighter joint assembly and increased resistance against loosening as a result of vibration.

[0025] In one implementation, the self-tapping thread 20 includes a symmetric thread angle per FIG. 6 (with the leading flank 20a forming angle 1 and trailing flank 20b forming 2, with 1=2) and a thread edge 20c that defines a trilobular thread edge profile in end view (FIG. 7showing lobes 30a, 30b and 30c) that is out of round (with round represented by line 31). In another implementation, the self-tapping thread includes a symmetric thread angle (FIG. 6) and a circular thread edge profile in end view. In either case, by way of example, the symmetric thread angle may be between about thirty and about forty-eight degrees (such as between about thirty-five and forty-five degrees). The smaller symmetric thread angle (as compared to sixty degrees of FIG. 1) results in increased pull-out force and also better joint assembly.

[0026] In another implementation, the self-tapping thread includes an asymmetric thread angle (FIG. 8, where leading flank angle 3>trailing flank angle 4). By way of example, the self-tapping thread may include a leading flank 20a defining a leading flank angle 3 of between about twenty and about twenty-five degrees, and a trailing flank 20b defining a trailing flank angle 4 of between about ten and about fifteen degrees. In one variation of this implementation the self-tapping thread includes a trilobular thread edge profile in end view (FIG. 7). The combination of the tapered self-drilling tip, asymmetric thread angle and trilobular thread edge profile in end view provides a unique configuration with fast penetration into thicker sheet metals with reduced torque, which reduces battery consumption for powered install tools, and the combination also provides better joint assembly. In another variation of this implementation, the self-tapping thread includes a circular thread edge profile in end view.

[0027] FIGS. 16 and 17 show another embodiment of a sheet metal screw 300, which is similar to screw 10, but with a different head configuration. The diametrically opposed flutes 324 are define by one planar surface 325 and one curved surface 327, where the radially outer edge of the planar surface 325 defines the primary cutting edge of each flute. The flutes 24 of sheet metal screw 10 may be of a similar form.

[0028] Referring to FIG. 9, another embodiment of a sheet metal screw 50 is shown. The screw includes a head end 52, a shank 54 and an entry tip end 56. The head end 52 includes a tool engaging part 58 (e.g., in the form of a drive receiving recess) and is located at one end of the shank 54, and the entry tip end 56 is located at an opposite end of the shank 54. The shank 54 includes a first portion 54a that runs from proximate to the head and includes a helically extending self-tapping thread 60, and a second portion 54b that runs from the first portion to the entry tip end and forms a self-drilling tip 66 that is unthreaded. The shank includes at least one flute 64 (typically two diametrically opposed flutes) on the self-drilling tip, where the flute runs from the entry tip end 56 toward the first portion 54a of the shank. In one embodiment, a base diameter D3 of the shank along the first portion 54a is substantially uniform and the shank includes the same substantially uniform base diameter D4 along the major portion of the self-drilling tip 66 (i.e., the self-drilling tip 66 does not include a taper). However, an entry tip segment 66a of the self-drilling tip 66 may be defined by an entry taper with angle 5 of between about one-hundred five and about one-hundred fifteen degrees, where the axial length L66a of the entry tip segment may be no more than twenty percent of an axial length L66b of the self-drilling tip. In an alternative embodiment, base diameter D4 could be substantially uniform, but slightly less the base diameter D3, in which case a slight step down (e.g., radial step or radial and slightly axial step) would be provided between shank portion 54a and shank portion 54b).

[0029] The self-tapping thread 60 includes a trilobular thread edge profile in end view FIG. 11, showing lobes 70a, 70b and 70c). In one implementation, the self-tapping thread includes a symmetric thread, with total thread angle of between about thirty and about forty-eight degrees, such as between about thirty-five and forty-five degrees, (FIG. 10, leading flank angle 5=trailing flank angle 6, and 5+6 defines the total thread angle). In another implementation, the self-tapping thread 60 includes an asymmetric thread angle (FIG. 12, leading flank angle 7>trailing flank angle 8). By way of example, the asymmetric thread may include a leading flank angle 7 of between about twenty and about twenty-five degrees, and a trailing flank angle 8 of between about ten and about fifteen degrees. The asymmetric thread angle provides increased resistance to pull-out and increased resistance to loosening as result of vibration.

[0030] Referring now to FIG. 13, another embodiment of a sheet metal screw 110 is shown and includes a head end 112, a pointed tip end 116 and shank 114 running between the head end and the pointed tip end. The head end includes a drive recess 118. The shank includes a primary portion 114a running from proximate the head toward end 116 and a tapered portion 114b running from the primary portion to the pointed tip. A self-tapping thread 120 runs helically from proximate to the head and along both the primary portion 114a and the tapered portion 114b to the pointed tip. The self-tapping thread has an asymmetric thread angle (FIG. 14, leading flank angle 9>trailing flank angle 10) and trilobular thread edge profile in end view (FIG. 15, with lobes 130a, 130b and 130c shown). The self-tapping thread 120 may include a leading flank angle of between about twenty and about twenty-five degrees, and a trailing flank angle of between about ten and about fifteen degrees. The combination of the asymmetric thread angle and trilobular thread edge profile in end view is a unique configuration that reduces torque to seat, increases resistance to pull-out, and thus provides a tighter and more robust joint assembly.

[0031] It is to be clearly understood that the above description is intended by way of illustration and example only, is not intended to be taken by way of limitation, and that other changes and modifications are possible. For example, while certain relative dimensions have been provided by example above, variations are possible. Moreover, while the screws shown above, such as screws 10 and 300, primarily contemplate a self-tapping thread of the single lead type (i.e., one thread spiral), it is recognized that screw variations with self-tapping threads other than single lead are possible. For example, the sheet metal screws could include threads that are double lead (i.e., two distinct thread spirals that extend along similar portions of the shank such that the thread lead is twice the thread pitch) or triple lead (i.e., three distinct thread spirals that extend along similar portions of the shank such that the thread lead is three times the thread pitch) could be incorporated into any of the above screws.