Molds and punches for making fasteners and tools

{
  "publication_number": "US11161169B2",
  "country": "US",
  "kind": "B2",
  "title": "Molds and punches for making fasteners and tools",
  "abstract": "A mold, punch and workpiece are provided. In a preferred embodiment, a tapering outer edge is provided, along with a plurality of rib sets arranged circumferentially about the outer edge, and a ramp. A ramp may be located to facilitate the removal of burrs. Various slot patterns may be provided or formed, including star-shapes/Torx® slots. Using the present invention, a driver bit may be more securely fit to the slot of a screw, for example, allowing the screw to be threaded into a machined part more securely and smoothly, reducing rocking, shaking or tilt.",
  "claims": [
    "1. A punch extending from a mold for stamping a screw with a slotted head to form a generally star-shaped pattern, comprising: a plurality of arcuate rib sets arranged circumferentially about an outer edge of the punch, wherein each rib set includes at least one arcuate main rib adjacent at least one rare arcuate subrib, and wherein the punch has a tapered portion comprising an outer edge of the punch that inwardly tapers from a lower end of the outer edge to an upper end of the outer edge, causing at least a portion of the punch to have a frustoconical shape; and a ramp formed between the punch and the outer edge of the punch, wherein a diameter of the ramp is larger than the diameter of the outer edge of the punch; wherein the outer edge of the punch forms an angle of between about 2°-3° with a longitudinal axis parallel to a length of the mold.",
    "2. The punch of claim 1, wherein the outer edge of the upper end of the punch forms a generally star-shaped pastern.",
    "3. A punch extending from a mold for stamping a screw with a slotted head to form a generally star-shaped pattern, comprising: a plurality of arcuate rib sets arranged circumferentially about an outer edge of the punch, wherein each rib set includes at least one arcuate main rib adjacent at least one arcuate subrib, wherein a ratio of a width of an arc of the main rib to a width of an arc of the subrib, for each rib set, is between about 1.5:1 and 2.5:1 and wherein the punch has a tapered portion comprising an outer edge of the punch that inwardly tapers from a lower end of the outer edge to n upper end of the outer edge, causing at least a portion of the punch to have a frustoconical shape; and a ramp formed between the punch and the outer edge of the punch, wherein a diameter of the ramp is larger than the diameter of the outer edge of the punch; wherein the punch comprises a distal end with a conical head, and a smooth edge is formed between the conical head and the distal end."
  ],
  "description_excerpt": "The present invention generally relates to molds and punches, and the fasteners, screwdriver heads and bits made using them, which employ a Torx®-shaped slot.\n\nAs background, drawn wire is pulled to a certain thickness or gauge, and a “header” punch is used to form the head and length of the screw. Threads are formed on the length of the screw using a rolling die. A slot may be formed on the screw head, typically using a stamping process. The stamping process may be a two-stage forming process, utilizing “primary” punches and “secondary” punches. The primary punch provides a positioning-point slot for positioning the secondary stamping. The secondary punch provides the secondary stamping, which forms the slot on the head of the fastener, for example. If the slot is properly designed, a driver bit may be inserted into and fit to the slot in a secure and stable manner, so that the driver bit can be used to firmly and securely rotate the fastener.\n\nThe shape of the slot of screws can be slotted, crossed, hexagonal, Torx®, etc. The so-called Torx® slot is a star-shaped slot with at least 6 lobes. As background, Torx®-head screws resist cam-out better than Phillips-head or slot-head screws. While Phillips heads were designed to cause the driver to cam-out, to prevent overtightening, Torx® heads were designed to prevent cam-out. Thus, rather than rely on the tool to slip out of the screw head when a predetermined torque level is reached, which risks damage to the driver tip, screw head and/or workpiece, torque-limiting driver designs achieve a desired torque consistently.",
  "cpc": [
    "B21K 1/463",
    "B25B 15/005",
    "F16B 23/003",
    "F16B 35/06"
  ],
  "ipc": [
    "B21K 1/46",
    "B25B 15/00",
    "F16B 23/00"
  ],
  "assignees": [
    "Phillips Fastener LLC"
  ],
  "inventors": [
    "Michael J Ross",
    "Chen Hung Lin",
    "Kuo Yung Yu"
  ],
  "filing_date": "2019-10-29",
  "publication_date": "2021-11-02",
  "grant_date": "2021-11-02",
  "priority_date": "2017-06-13",
  "application_number": "US-201916667122-A",
  "family_id": "60153124",
  "cited_by_count": 0,
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    "US20180347611A1"
  ]
}