Field of the invention

The invention relates to a screw head having a slot in its upper surface with a recess disposed inwardly of the slot, to a tool for use with this screw head, and to a system comprising a screw head and a tool for use therewith.

Background of the invention

The state of the art includes WO 2007/123409 Al , describing a system for driving a screw. The system comprises a screw and a corresponding tool, where the screw head comprises a hexalobular slot and a sloping transition surface extending downwardly and inwardly with respect to the slot, and a tapered recess extending downwardly from the lower edge of the sloping transition surface. When the screw head is engaged by a tool having upper and lower engagement sections, and where the upper engagement section is tapered downwardly at an angle, and the lower engagement section is tapered downwardly, there is a 'stick fit' between the surface of the tapered recess and the external surface of the lower tapered engagement section, and there is no engagement with the sloping transition surface.

Summary of the invention

It is therefore provided a system for driving a screw, comprises a screw and a corresponding tool, wherein the screw comprises a screw head having a hexalobular slot in the upper surface of the screw head, an upper peripheral wall of hexalobular planform extending down into the screw head, the upper peripheral wall being parallel or near parallel to the axis of the screw, a sloping transition surface extending downwardly and inwardly with respect to the lower edge of the upper peripheral wall, and a tapered recess extending downwardly from the lower edge of the sloping transition surface. The dimensions of the screw head are such that when the screw head is engaged by the tool, which has upper and lower engagement sections and in which the upper engagement section fits within a recess formed in the hexalobular slot, there is an interference fit between the surface of the tapered recess and the external surface of the lower engagement section, and there is no engagement with the sloping transition surface.

In one embodiment, the upper engagement section comprises a uniform diameter. In one embodiment, the upper engagement section is tapered downwardly at an angle with respect to the axis of the screw.

In one embodiment, in the lower engagement section of the tool, the tool is tapered at the same angle as the recess in the screw, so that the tool makes an interference fit press connection with the screw. There is a transition zone between the upper and lower engagement sections of the tool in which the tool makes no contact with the screw. In one embodiment, in the upper engagement section of the tool, the tool is tapered at a sharper angle than the peripheral wall of the screw.

In one embodiment, there is a closer fit at the upper edge of the upper peripheral wall than a fit at the lower edge of the upper peripheral wall with the upper engagement section.

The external surface of the lower engagement section has a shape which

substantially matches any of a plurality of angular inclinations the surface of the tapered recess may have where the interference fit occurs between the external surface of the lower engagement section and the surface of the tapered recess.

Within an axial cross-section of the tool, the external surface of the lower engagement portion preferably has a first curved portion where the interference fit occurs between the external surface of the lower engagement section and the surface of the tapered recess.

It is also provided a tool for driving a screw having a hexalobular-shaped first recess extending into a screw head and a second recess at the bottom of the first recess, the tool comprising: an upper engagement section configured to fit within the first recess; and a lower engagement section connected to the upper engagement section via a surface extending from the lower engagement section to the upper engagement section; wherein the lower engagement section is tapered downwardly.

In one embodiment, the second recess comprises a circular cross section and the lower engagement section comprises a circular cross section.

In one embodiment, the upper engagement section is tapered downwardly at an angle with respect to the axis of the screw.

It is also provided a screw, comprising screw head; a hexalobular-shaped first recess extending into the screw head; and a second recess centrally located at the bottom of the first recess; wherein the second recess comprises inclined walls, and a bottom of the second recess has a diameter smaller than that of an upper part of the second recess.

In one embodiment, the second recess comprises a circular shape. In one

embodiment, a downward transition surface is formed between the upper part of the second recess and walls of the first recess. In one embodiment, the transition surface is parallel with respect to an axis of the screw. In one embodiment, the transition surface is angled with respect to an axis of the screw. In one embodiment, a downward transition surface is formed between the upper part of the second recess and walls of the first recess. It is also provided a tool for engaging a screw; the screw having a hexalobular slot in the upper surface of a screw head and an upper peripheral wall of hexalobular planform extending down into the screw head, the upper peripheral wall being substantially parallel to the axis of the screw; a sloping transition surface extending downwardly and inwardly with respect to the lower edge of the upper peripheral wall; and a tapered recess extending downwardly from the lower edge of the sloping transition surface, the tool comprising an upper engagement section which fits within a recess formed in the hexalobular slot; and a lower engagement section; wherein the dimensions of the tool are such that when the screw head is engaged by the tool with the upper engagement section within the recess, there is an

interference fit between the surface of the tapered recess and the external surface of the lower engagement section and there is no engagement with the sloping transition surface.

In one embodiment, the upper engagement section comprises a uniform diameter. In one embodiment, the upper engagement section is tapered downwardly at an angle with respect to the axis of the screw.

In one embodiment, in the lower engagement section of the tool, the tool is tapered at the same angle as the recess in the screw, so that the tool makes an interference fit press connection with the screw. Preferably, there is a transition zone between the upper and lower engagement sections of the tool in which the tool makes no contact with the screw.

In one embodiment, there is a closer fit at the upper edge of the upper peripheral wall than a fit at the lower edge of the upper peripheral wall with the upper engagement section.

It is also provided a screw for engagement by a tool, the tool having an upper engagement section and a lower engagement section, the screw comprising: a hexalobular slot in the upper surface of the screw head within an upper peripheral wall of hexalobular planform extending down into the screw head, the upper peripheral wall being substantially parallel to the axis of the screw, wherein a recess formed in the hexalobular slot is configured to receive the upper engagement section of the tool; a sloping transition surface extending downwardly and inwardly with respect to the lower edge of the upper peripheral wall; and a tapered recess extending downwardly from the lower edge of the sloping transition surface;

wherein the dimensions of the screw head are such that when the screw head is engaged by the tool with the upper engagement section of the tool within the recess formed in the hexalobular slot, there is an interference fit between the surface of the tapered recess and the external surface of the lower engagement section, and there is no engagement with the sloping transition surface. In one embodiment, the tapered recess is tapered at the same angle as the lower engagement section of the tool, so that the tool makes an interference fit press connection with the screw.

In one embodiment, the dimensions of the screw head are such that, when the tool is engaged to the screw, a transition zone of the tool between its upper and lower engagement sections makes no contact with the screw.

In one embodiment, the peripheral wall of the screw extends at a smaller angle than the upper engagement section of the tool. The tapered recess may be of a circular planform.

In one embodiment, when the tool is engaged to the screw, there is a closer fit at the upper edge of the upper peripheral wall than a fit at the lower edge of the upper peripheral wall with the upper engagement section. The tapered recess is preferably of a circular planform.

It is also provided a system for driving a screw, comprising a screw and a

corresponding tool, wherein the screw includes a screw head comprising: a slot in the upper surface of the screw head, a tapered recess disposed downwardly of the slot in the screw, and wherein the tool comprises: an upper engagement section which fits within the slot, and a lower engagement section shaped to extend into the tapered recess with a contact surface of an external surface of the lower engagement section in an interference fit with the tapered recess when the upper engagement section is disposed within the slot, the contact surface having a shape which substantially matches any of a plurality of angular inclinations the surface of the tapered recess may have at the interference fit.

In one embodiment, within an axial cross-section of the tool, the contact surface includes a first curved portion. The first curved portion may have a substantially constant radius of curvature, or may have a varying radius of curvature.

In one embodiment, the slot has a hexalobular shape, and the upper engagement section of the tool has a hexalobular shape. In one embodiment, within an axial cross-section of the screw, the tapered recess has a curved portion that abuts the contact portion of the lower engagement section of the tool at the interference fit.

It is furthermore provided a tool for engaging a screw; the screw having a slot in the upper surface of a screw head and a tapered recess disposed downwardly of the slot, the tool comprising: an upper engagement section designed to fit within the slot, and a lower engagement section shaped to extend into the tapered recess with a contact surface of an external surface of the lower engagement section in an interference fit with the tapered recess when the upper engagement section is disposed within the slot, wherein within an axial cross-section of the tool, the contact surface includes a first curved portion.

In one embodiment, the upper engagement section of the tool has a hexalobular shape. The first curved portion may have a substantially constant radius of curvature, or may have a varying radius of curvature.

It is also provided a screw for engagement by a tool, the tool having an upper engagement section and a lower engagement section, the screw comprising a slot in the upper surface of the screw head within an upper peripheral wall extending down into the screw head, wherein the slot is shaped to receive the upper engagement section of the tool; and a tapered recess disposed downwardly of the slot, wherein within an axial cross-section of the screw, the tapered recess has a curved portion; wherein the dimensions of the screw head are such that when the screw head is engaged by the tool with the upper engagement section of the tool within the slot, there is an interference fit between the curved portion of the surface of the tapered recess and the external surface of the lower engagement section.

In one embodiment, the slot has a hexalobular shape. In one embodiment, the screw head further includes a sloping transition surface extending downwardly and inwardly with respect to the lower edge of the upper peripheral wall toward the tapered recess, and the dimensions of the screw head are such that when the screw head is engaged by the tool with an interference fit between the surface of the tapered recess and the external surface of the lower engagement section, there is no engagement of the tool with the sloping transition surface.

There is provided a screw head having a hexalobular slot in the upper surface of the screw head, an upper peripheral wall of hexalobular planform extending down into the screw head, the upper peripheral wall being parallel or near parallel to the axis of the screw, a sloping transition surface extending downwardly and inwardly with respect to the lower edge of the upper peripheral wall, and a tapered recess extending downwardly from the lower edge of the sloping transition surface, in which the dimensions of the screw head are such that when the screw head is engaged by a tool having upper and lower engagement sections, there is a 'stick fit' (i.e., an interference fit) between the surface of the tapered recess and the external surface of the lower engagement section, and there is no engagement with the sloping transition surface.

The invention provides a tool for use with a screw head having a hexalobular slot in its upper surface, and in which the tool has upper and lower engagement sections, and the lower engagement section is of smaller diameter is and tapered downwardly with respect to the axis of the screw to which the tool is to engage, and in which the upper and lower engagement sections are connected with a transition surface which is tapered with a large angle with respect to the axis of the screw. The upper engagement section may be tapered downwardly at an angle or may be straight with respect to the axis of a screw to which the tool is to engage. The upper engagement section may be tapered at an angle of 0.1 to 5 degrees, or at an angle of between 1 and 2 degrees.

In one embodiment, in an upper engagement section of the tool, the tool is tapered at a sharper angle than a peripheral wall of the screw.

Brief description of the drawings

These and other characteristics of the invention will be clear from the following description of preferential forms of embodiments, given as non-restrictive examples, with reference to the accompanying drawings, in which: -

Figure 1 is a cross section of one embodiment of a driving tool,

Figure 2 is a cross section of the tool of Fig. 1 engaging the head of a screw,

Figure 3 is a plan view of the screw head showing the configuration of a slot, Figure 4 is a cross section of another embodiment of a driving tool,

Figure 5 is a cross section of the tool of Fig. 4 engaging the head of a screw,

Figure 6 is a cross section of another embodiment of a driving tool,

Figure 7 is a cross section of the tool of Fig. 6 engaging the head of a screw,

Figure 8 shows a central point of another embodiment of a driving tool engaged in a tapered recess of the head of a screw,

Figure 9 shows a central point of another embodiment of a driving tool engaged in a tapered recess of the head of a screw, and

Figure 10 is a cross section of another embodiment of a driving tool engaging, another embodiment of a screw.

Description of preferential embodiments

As shown in Figures 2, 5, 7, and 10, a screw head 1 has a slot 2. The slot 2 is formed as a recess 3 in the screw head, and is shaped as a star with six points 4. The points 4 of the star are rounded, as shown in Figure 3, and the slot 2 is termed a hexalobular slot. As used herein, the terms "rounded" and "round" are not limited to shapes having a constant radius of curvature but refer to any curved shape, including elliptical or other curved shapes. Hexalobular slots are described in ISO 10664, and are an internal driving feature. They may be known as 'teeth recesses' or 'star recesses'. Depending on the direction of rotation, a tool 6 (see Figures 1 -3) will engage surfaces 7 or 8 on one side or the other of each point 4.

Figure 2 shows a cross section through one embodiment of the screw head 1. The recess 3 extends down into the screw head 1. Walls 9 of the recess 3 are

approximately straight. The cross section of the recess 3 retains the shape of a star with six points throughout the straight walled part as it extends down into the screw head. The depth of the recess 3 is limited by the minimum allowable wall thickness 10 near the bottom of the recess 3.

As shown in Figures 2, 5, 7, and 10, the slot 2 has a further recess 1 1 at the bottom of the six pointed recess 3. The recess 1 1 is aligned with the axis of the screw, and so is centrally located therein. This central recess 1 1 may have a circular cross section and a smaller diameter than the recess 3. Walls 12 of the recess 1 1 are slightly inclined, so that the bottom 13 of the recess 11 has a diameter slightly smaller than that of the upper part 14 of the recess 1 1.

The walls 12 of the recess 1 1 may have various shapes. For example, within an axial cross-section of the screw head 1 , the walls 12 may extend in substantially straight lines, as shown in Figures 2, 5, and 7. As another example, the walls 12 may extend at different angles at different points along the axis of the screw head 1, as shown in Figure 10. In some such cases, the walls 12 may have a convex shape and extend away from the axis of the screw head 1 as they extend upwardly. For example, as Figure 10 shows, the walls 12 may include one or more curved portions that extend away from the axis of the screw head 1 as they extend upward. In embodiments where the walls 12 include on or more curved portions, those portions may have a constant or varying radius of curvature.

The configuration of the walls 12 of the tapered recess 1 1 is not limited to the examples provided in the Figures. For instance, as an alternative to one or more curved, convex portions extending away from the axis of the screw head as they extend upward, the walls 12 of the tapered recess 1 1 may include one or more polygonal portions that extend at an increasing angle to the axis of the screw head as they extend upward. Indeed, the walls 12 of the tapered recess may have any combination of straight, curved, and/or polygonal portions that allow an

interference fit with the tool 6, as discussed in more detail below.

A downwardly straight or sloping transition surface 15 is formed between the upper part 14 of the central recess 1 1 and the walls 9 of the six-pointed recess 3.

The tool 6 has an engagement section 16 that is designed to fit within the recess 3. The shape of the engagement section 16 in plan complements the shape of the recess 3. The diameter (in cross-section; or circumference) of the engagement section 16 may be uniform (as shown in Figures 4-7) or slightly tapered inwardly towards its lower end (as shown in Figures 1 and 2). The taper may typically be 1.5 degrees. The diameter of the engagement section 16 is sized to allow it to be inserted into the recess 3 without difficulties.

The tool 6 also has a central point, or lower engagement section, 17, which may have a circular cross section. A surface 18 on the tool 6 extends outwardly and upwardly from the central point 17 to the engagement section 16. The angle of inclination of the surface 18 is smaller than that of the transition surface 15. Thus a space 19 is formed between the surfaces 15 and 18 when a tool 6 is inserted into the slot 2. The depth of the space 19 diverges towards the central point 17. The section 16 of the tool 6 may engage the upper periphery of the walls 9 of the recess 3 when the tool enters the slot 2.

Furthermore, in the case of screws which have undergone surface treatment, the diverging space 19 allows any excess coating to collect in the space 19 without obstructing the engagement between the tool and the slot. If no space had been provided, coating residue might settle on the surface 15 and at the bottom 13 of the recess 1 1 , and thereby prevent sufficient engagement between the tool 6 and the slot 2.

Press engagement between the central point 17 and the recess 1 1 , supported by the engagement section 16 of the tool and the upper periphery of the wall 9, ensures that - due to friction - the screw can remain (i.e. 'stick fit') on the tool without falling off. This mode of engagement is particularly effective in reducing angular movement between the tool 6 and the screw head 1. Retention of the screw on the tool by press engagement is particularly useful on one handed power tools and for robotic tools.

To provide an interference fit between the central point 17 and the tapered recess 1 1 , one or more portions of the central point 17 may have a cross-sectional dimension wider than the narrowest portion of the tapered recess 1 1 and narrower than the widest portion of the tapered recess 1 1. As a result, one or more contact surfaces 30 of an external surface of central point 17 may provide an interference fit with the tapered recess 1 1 where the contact surface 30 presses against the surface of the tapered recess 1 1. The contact surfaces 30 of the central point 17 may have various shapes. For example, as Figures 1 , 2, 4, and 5 show, within an axial cross- section of central point 17, contact surfaces 30 may have straight sides, which may taper toward one another as they extend downward. In some embodiments, these straight sides may have substantially the same taper as the surface of the tapered recess 1 1.

Alternatively, different portions of the contact surfaces 30 may extend at different angles relative to the axis of the tool 6 and the screw head 1. For example, as Figures 6-9 show, the contact surfaces 30 may include one or more curved portions within an axial cross-section of the central point 17. The one or more curved portions of each contact surface 30 may have a convex shape that extends at an increasingly greater angle to the axis of the tool and the screw head as it extends downwardly. For instance, contact surfaces 30 may include convex curved portions that curve toward the axis of the tool 6 and the screw head 1 1 as they extend downward.

Configuring the contact surfaces 30 and/or the walls 12 of the tapered recess 1 1 with a shape having different angles at different axial points, such as a curved surface, may allow the contact surfaces 30 to substantially match any of a plurality of angles that the surface of the tapered recess 1 1 may have at the point of the interference fit. Indeed, configuring the contact surfaces 30 and/or the walls 12 of the tapered recess 1 1 with a curved cross-section may allow the contact surfaces 30 to automatically substantially match whatever angle the corresponding portion of the surface of the tapered recess 1 1 may have at the point of interference fit between the contact surfaces 30 and the surface of the tapered recess 1 1. With the contact surfaces 30 and/or the walls 12 of the tapered recess 1 1 having convex, curved shapes, contact between the contact surfaces 30 and the walls 12 of the tapered recess 1 1 will automatically occur wherever the two surfaces are tangent to one another. Thus, at the point of the interference fit, the contact surfaces 30 will extend parallel to the abutting portion of the walls 12 of the tapered recess 11, regardless of the angle of the contact surfaces 30 or the walls 12.

Embodiments of the tool 6 where the contact surface 30 includes one or more curved portions may have various forms. As shown in Figures 6-8, the central point 17 may include a single, curved bulb 32 with curved contact surfaces 30 on each side. As another example, Figures 9 and show that the central point 17 may include multiple curved bulbs 34, 36, each defining curved contact surfaces 30. A curved portion of a contact surface 30 may have a substantially constant radius of curvature, as shown in Figure 9, or it may have a varying radius of curvature, as shown in Fig. 8. Indeed, curved portions of contact surfaces 30 may include one or more circular shapes, elliptical shapes, or segments of such shapes. The remainder of the central point 17 may have any shape, including, but not limited to, tapered, non-tapered, and/or non-circular (in its cross-section perpendicular to the central axis of tool 6).

The configuration of the central point 17 and the contact surfaces 30 are not limited to the examples provided in the Figures. The central point 17 and the surfaces thereof, including the contact surfaces 30, may be smooth, uneven (rough), fluted (grooved), and/or any other shape and/or textures. The contact surfaces 30 may have any arrangement of shapes that allow it to engage with the surface of the tapered recess 1 1. For instance, as an alternative to a curved portion, a contact surface 30 may have a portion with a polygonal cross-section that extends toward the axis of the tool 6 as it extends downwardly. Similar to a curved portion, such a polygonal portion may allow the contact surface to match any of a plurality of different angles that the surface of the tapered recess 1 1 may have at the point of the interference fit. Furthermore, in the case of straight-side contact surfaces 30, the contact surfaces 30 may extend at angle(s) different from the angle of the surface of the tapered recess 1 1.

Additionally, a system according to the present disclosure may employ different combinations of shapes of the contact surfaces 30 of the central point 17 and the walls 12 of the tapered recess 1 1 than shown in the Figures. For example, a system according to the present disclosure may employ a central point 17 with contact surfaces 30 that are substantially straight with walls 12 of the tapered recess 1 1 that include curved and/or polygonal portions.

The central point 17 may have a length shorter than the height of the recess 3, to enable the engagement section 16 of the tool 6 to enter the recess 3.

The formation of a conical press connection between the tool 6 and the screw head 1 enables the screw to remain on the tool, and not fall off. Force fit of the tool 6 onto the screw head 1 keeps the screw head on the tool. The material of the tool 6 is harder than the material of the screw head 1, and this enables the force fit connection to take place.

Additionally, configuring the contact surfaces 30 and/or the walls 12 of the tapered recess 1 1 with a cross-section that has different angles at different axial positions, such as with one or more curved portions, may provide a cost-effective way to ensure secure engagement of the tool 6 to the screw head 1. By allowing the contact surfaces 30 to automatically match the angle of the tapered recess 1 1 at the point of the interference fit, such a configuration may ensure desirably high friction between the contact surfaces 30 of the central point 17 and the walls 12 of the tapered recess 1 1. This result may occur because surfaces extending at substantially the same angle where they abut may tend to produce greater friction than surfaces extending at significantly different angles where they abut. This may promote good adherence of the screw head 1 to the tool 6. Because the disclosed embodiments enable this result for a variety of angles that the contact surfaces 30 of the central point 17 and/or the walls 12 of the tapered recess 1 1 may have, they reduce the need to hold tight manufacturing tolerances on the shapes of these surfaces.

Additionally, configuring the contact surfaces 30 with one or more convex portions that extend at increasingly greater angles to the axis of the tool 6 as they extend downward may tend to reduce variability in the depth of engagement of the central point 17 in the tapered recess 1 1. Configuring the walls 12 of the tapered recess 1 1 with one or more convex portions that extend away from the central axis of the screw head 1 as they extend upward may also promote this result. This may help ensure that the tool 6 properly engages the screw head 1 to allow robust transfer of torque between the tool 6 and the screw head 1.