Screw with breakaway and methods of using the same

A fastener with a breakaway and methods of using the same. In one embodiment the fastener is a screw having a head and elongated stem, adapted to be easily manipulated by a user when using the screw as a fastener in a hinge or joint. A means of holding a screw by providing a breakaway tab or non-threaded second portion of the elongated stem which can be used to align and insert the screw into a screw hole in the process of engaging threads in the screw hole with threads of the screw. After engaging the threads in the screw hole, such as after the screw has been essentially completely inserted into the screw hole, the breakaway tab or non-threaded second portion of the elongated stem of the screw may be broken off at a breakaway and discarded.

FIELD OF THE INVENTION

The present invention relates generally to fasteners. More specifically, the invention relates to screws and their use in joints.

BACKGROUND

Small, hand held fastening devices are used in the mechanical and construction industries.

There is an increasing need for adaptations that facilitate the manipulation of such small, hand held fastening devices.

SUMMARY OF THE INVENTION

A first aspect of the present invention provides a screw, comprising: a screw head, comprising: a first surface having a driver slot thereon, and a second surface, wherein the second surface of the screw head faces away from the first surface; an elongated stem, comprising: either a threaded first portion and a non-threaded second portion extending from the distal end of the threaded first portion and a first breakaway therebetween, wherein a proximal end of the threaded first portion is mechanically and physically coupled to the second surface of the screw head, wherein the physical coupling between the second surface of the screw head and the proximal end of the threaded first portion is not a breakaway, wherein the first breakaway releasably couples the non-threaded second portion to the distal end of the threaded first portion, or a threaded first portion, without the non-threaded second portion extending from the threaded first portion and a second breakaway, wherein a proximal end of the threaded first portion is non-releasably mechanically and physically coupled to the second surface of the screw head, wherein the mechanical and physical coupling between the second surface of the screw head and the proximal end of the threaded first portion is not a breakaway, and wherein the second breakaway releasably couples the first surface of the screw head to a breakaway tab.

A second aspect of the present invention provides a method of replacing a screw in a hinge, comprising: providing a hinge, comprising: first and second straps, pivotably coupled to a cylinder, wherein the cylinder has a threaded hollow channel therein; providing a screw comprising: a head; an elongated stem comprising: either a threaded first portion adjacent to the head; and a non-threaded second portion extending from the threaded first portion; and a first breakaway therebetween, wherein the first breakaway releasably couples the non-threaded second portion to the distal end of the threaded first portion, or a threaded first portion adjacent to the head without the non-threaded second portion extending from the threaded first portion and a second breakaway, wherein the second breakaway releasably couples the first surface of the screw head to a breakaway tab; inserting the non-threaded second portion of the elongated stem into the hollow threaded channel in the hinge so that the non-threaded second portion of the elongated stem extends out of the hollow threaded channel of the hinge; or inserting the threaded portion of the elongated stem into the hollow threaded channel in the hinge by a user manipulating the insertion using the breakaway tab; aligning the threaded first portion of the elongated stem with the threads of the hollow threaded channel of the hinge; and screwing the first threaded portion of the elongated stem into the hollow threaded channel of the hinge by rotating the threaded first portion of the elongated stem that has been aligned with the threads of the threaded hollow channel of the hinge.

A third aspect of the present invention provides a kit, comprising: a hinge, comprising first and second straps, pivotably coupled to a cylinder, wherein the cylinder has a threaded hollow channel therein; a screw, comprising: a head; an elongated stem, comprising: either a threaded first portion adjacent to the head and a non-threaded second portion extending from the threaded first portion and a first breakaway therebetween, wherein the first breakaway releasably couples the first threaded portion of the elongated stem to the non-threaded second portion of the elongated stem, wherein the non-threaded second portion of the elongated stem has been aligned with the hollow threaded channel in the hinge, and wherein the non-threaded second portion of the elongated stem has been inserted into the hollow threaded channel in the hinge so that the threaded first portion of the elongated stem catches at least one of the threads of the hollow threaded channel of the hinge; or a threaded first portion physically and mechanically non-releasably coupled to the second surface of the screw head without the non-threaded second portion extending from the threaded first portion and a second breakaway, wherein the second breakaway releasably couples the first surface of the screw head to a breakaway tab, wherein the proximal end of the threaded portion and the second surface of the screw head are non-releasably coupled, and wherein the threaded first portion of the elongated stem has caught at least one thread of the hollow threaded channel of the hinge, by threading the threads of the first portion of the elongated stem with the threads of the hollow threaded channel.

A fourth aspect of the present invention provides a system for guiding a screw into a hinge, comprising: a hinge, wherein the hinge has a hollow channel therein; a screw, comprising: a head; an elongated stem, comprising: a threaded first portion adjacent to the head; and a non-threaded second portion extending from the threaded first portion; and a breakaway, wherein the breakaway is removably connected therebetween or removably connected to the first surface of the screw head, but the breakaway is not removably connected between the threaded first portion of the elongated stem and the head of the screw, wherein the non-threaded second portion of the elongated stem has been aligned with the hollow threaded channel in the hinge, wherein the non-threaded second portion of the elongated stem has been manipulated into the threaded hole in the hinge so that the threaded first portion of the elongated stem is articulated with the threads of the hollow threaded channel of the hinge, and wherein the screw has been inserted into the threaded first portion of the elongated stem by threading the threads of the first portion of the elongated stem with the threads of the threaded hole.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

FIG. 1Adepicts a top plan view of a first surface19of a screw head15of a screw10. The screw head15includes a driver slot17. The screw10may be a round head15made of stainless steel, brass, nickel/sliver, carbon steel, titanium, or other appropriate metals or metal alloys. The driver slot17may be a single groove, a Phillips® cross shaped groove, an hexagonal groove for turning with a hex wrench.

FIG. 1Bdepicts a longitudinal cross-sectional view of the screw10. The screw10, comprises: the screw head15, comprising: a first surface19having a driver slot17thereon, and a second surface18, wherein the second surface18of the screw head15faces away from the first surface19. The screw10comprises an elongated stem11. The elongated stem11comprises a threaded first portion20. A proximal end A of the threaded first portion20is mechanically and physically coupled to the second surface18of the screw head15. The mechanical and physical coupling between the second surface18of the screw head15and the proximal end A of the threaded first portion20is not a breakaway25,43. The elongated stem11comprises a non-threaded second portion30extending from a distal end C of the threaded first portion20; and a breakaway25therebetween.

Hereinafter, a “breakaway” is defined as a releasable coupling between a removable piece such as the proximal end12of the non-threaded second portion30and the distal end C of the threaded first portion20. Hereinafter, “distal end” is defined as the further point along the elongated stem11in reference to the second surface18of the screw head15, and “proximal” is defined as the nearer point along the elongated stem11in reference to the second surface18of the screw head15.

Hereinafter “releasably coupling” is defined as forming or breaking or cleaving or severing a mechanical and physical coupling between the removable piece such as the proximal end12of the non-threaded second portion30and the distal end C of the threaded first portion20.

Hereinafter “screwing the screw10,13into a screw hole59,100or threaded hollow channel of a hinge64” is defined as engaging the threads63in the screw hole59,100or hollow threaded channel64of a hinge66, by rotating the screw10,13about its longitudinal axis in a clockwise motion, resulting in the screw10,13being essentially completely inserted into the screw hole59,100or hollow threaded channel64of the hinge66. Such engaging the threads63in the screw hole or hollow threaded channel64has the ultimate end that the screw10,13has been essentially completely inserted into the screw hole59,100.

In one embodiment, the screw10comprises a non-threaded second portion30for making it easier to handle the screw10. You insert the non-threaded second portion30of the screw10into a screw hole100first and then you are able to pull the threaded first portion20of the screw10into the screw hole100as the non-threaded second portion30is removed from the screw hole100. This adapts the screw10to be more easily manipulated by hand by a user.

In one embodiment, a length L1from about 0.3375 in. to about 0.4125 in. may separate the proximal end A of the threaded first portion20and the distal end C of the threaded first portion20.

In one embodiment, a length L2from about 0.6973 in. to about 0.8525 in. may separate the proximal end A of the threaded first portion20and the distal end B of the non-threaded second portion30of the elongated stem11.

In one embodiment, a diameter W3of the non-threaded second portion30is preferably smaller than a diameter W2of the threaded first portion20of the elongated stem11. In one embodiment the diameter W3is from about 0.036 in. to about 0.044 in.

In one embodiment an axial cross-section of the non-threaded second portion30is substantially circular. In this embodiment, an outer surface27of the non-threaded second portion30is substantially smooth.

FIG. 2Adepicts a front longitudinal view of a screw13. The screw13comprises: a screw head50and an elongated stem14. The screw head50, comprises: a first surface44having a driver slot51thereon. The screw head50, comprises a second surface48, depicted inFIG. 3Aand described in associated text. The second surface48of the screw head50faces away from the first surface44. The elongated stem14, comprises: either a threaded first portion20and a non-threaded second portion30extending from the distal end C of the threaded first portion20and a first breakaway25therebetween, depicted inFIG. 1B, or a threaded first portion42, without the non-threaded second portion30, depicted inFIG. 1B, extending from the threaded first portion42and a second breakaway43. A proximal end E of the threaded first portion42is non-releasably coupled to the second surface48of the screw head50. The mechanical and physical coupling between the second surface48of the screw head50and the proximal end E of the threaded first portion42is not a breakaway25,43. In this embodiment, the first breakaway25releasably couples the non-threaded second portion30to the distal end C of the threaded first portion20.

In an alternative embodiment the threaded first portion42, without the non-threaded second portion30extends from the threaded first portion42and a second breakaway43. In this embodiment, a proximal end E of the threaded first portion-42is non-releasably mechanically and physically coupled to the second surface48of the screw head50. In this embodiment, the mechanical and physical coupling between the second surface48of the screw head50and the proximal end E of the threaded first portion42is not a breakaway25,43. In addition, the second breakaway43releasably couples the first surface48of the screw head50to a breakaway tab45.

In one embodiment, a screw13with a breakaway tab45on the screw head50guides screws13into a screw hole59for easy maneuverability. Any size screw13, or breakaway tab45may be placed anywhere on the head50of the screw13. Insert the screw13in hole59, turn the breakaway tab45to start the screwing operation and then break the breakaway tab45off.

In one embodiment, a length L5from the second surface48to the second breakaway43, releasably coupling the breakaway tab45, may be from about 0.1 in. to about 0.21 in.

In one embodiment, a width W7of the breakaway tab45may be from about 0.225 in. to about 0.275 in. and a length L3of the breakaway tab45may be from about 0.45 in. to about 0.55 in.

FIG. 2Bdepicts a top plan view of a first surface44of a screw head50of the screw13. The screw head50includes a driver slot51. The screw13may be made of stainless steel, brass, nickel/sliver, carbon steel, titanium, or other appropriate metals or metal alloys. The driver slot51may be a single groove, a Phillips® cross shaped groove, or an hexagonal groove for turning with a hex wrench.

FIG. 3Adepicts a side elevation view of the screw13. In one embodiment, a length L4from the proximal end E of the threaded first portion20to the distal end F of the threaded first portion42of the elongated stem14may be from about 0.3942 in. to about 0.4818 in.

In one embodiment, a face49of the breakaway tab45and a longitudinal plane of the driver slot51are parallel. A width W8of the driver slot51may be from about 0.045 in. to about 0.055 in. A ratio of the thickness L9of the breakaway tab45of the screw13to the width W8of the driver slot51is from about 0.3:1.0 to about 0.4:0.9.

In one embodiment, a ratio of the length L1of the threaded first portion20to a length of the non-threaded second portion30of the screw10is from about 1:1 to about 0.775:1. The length of the non-threaded second portion is defined as a length between proximal end12of the non-threaded second portion30and the distal end B of the non-threaded second portion30of the elongated stem11, as depicted inFIGS. 1B and 4, and described in associated text, herein.

In one embodiment, a diameter of the first breakaway25of the screw10is less than or equal to 0.015 in., when the diameter of the elongated stem11is essentially equal to 0.040 in.

In one embodiment, a ratio of the width W1of the breakaway tab45to a length L3of the breakaway tab45is from about 1:2 to about 1:10.

In one embodiment, the screw head50is a slotted undercut oval countersunk head.

In one embodiment, the threaded first portion42has a 6-32 UNF thread, wherein conventional UNC or UNF thread is a 60 degree thread.

In one embodiment, a ratio of the length L4of the threaded first portion42to the length L3of the breakaway tab45of the screw10is from about 1:1 to about 0.876:1.

FIG. 3Bdepicts a top plan view of a first surface44of a screw head51of the screw50. In one embodiment, a width W1of the second breakaway43across the first surface44of the screw head50, depicted inFIG. 2B, is from about 75% to about 95% of the length L10of the driver slot51thereon.

FIG. 4depicts a longitudinal cross-sectional view of a kit65. In one embodiment, the kit65comprises: a hinge66, comprising first and second straps60,61, pivotably coupled to a cylinder62. The cylinder62has a hollow threaded channel64therein. The kit65comprises: a screw10, comprising: a head19and an elongated stem11. The elongated stem11, comprises: either a threaded first portion20adjacent to the head15and a non-threaded second portion30extending from the threaded first portion20and a first breakaway25therebetween. The first breakaway25releasably couples the threaded first portion20of the elongated stem11to the non-threaded second portion30of the elongated stem11. The non-threaded second portion30of the elongated stem11has been aligned with the hollow threaded channel64in the hinge66. The non-threaded second portion30of the elongated stem11has been inserted into the hollow threaded channel64in the hinge66so that the threaded first portion20of the elongated stem11catches at least one of the threads63of the hollow threaded channel64of the hinge66.

The elongated stem14comprises a threaded first portion42physically and mechanically non-releasably coupled to the second surface48of the screw head50without the non-threaded second portion30, depicted inFIGS. 1A, B extending from the threaded first portion42and a second breakaway43. The second breakaway43releasably couples the first surface44of the screw head50to a breakaway tab45. The threaded first portion42of the elongated stem11has caught at least one thread63of the hollow threaded channel64of the hinge66, by threading the threads67of the threaded first portion20of the elongated stem11with the threads63of the hollow threaded channel64.

In all preferred embodiments, the proximal end E of the threaded first portion42and the second surface48of the screw head50are mechanically and physically non-releasably coupled.

In one embodiment, the breakaway tab45extends along a longitudinal axis of the screw13, away from the first surface44of the screw head50.

FIG. 5depicts a top plan view of a screw85having a screw head86. The screw head86has a first surface80and a driver slot81, therein. The screw head86is releasably coupled to a breakaway tab84, having a breakaway83therebetween. The breakaway tab84has a first surface79, and the first surface79may be coplanar with the first surface80of the screw head86.

FIGS. 6A-6Cdepict a flow diagram of a method90of replacing a screw10,13in a hinge66, depicted inFIG. 4, and described in associated text and depicted in FIGS.2A.-3B, and described in associated text. In a step92of the method90, a hinge66is provided. In the step92of providing the hinge66, first and second straps60,61may be pivotably coupled to a cylinder62. The cylinder62has a hollow threaded channel64therein;

In a steps96and98a screw10,13is provided. The screw10,13comprises: a head15,50; an elongated stem11,14.

In the steps96,98the elongated stem11,14comprises: either a threaded first portion20,42adjacent to the head15,50; and a non-threaded second portion30, extending from the threaded first portion20,42; and a first breakaway25therebetween, wherein the first breakaway25releasably couples the non-threaded second portion30to the distal end C of the threaded first portion20, or

a threaded first portion42adjacent to the head50without the non-threaded second portion30extending from the threaded first portion42and a second breakaway43, wherein the second breakaway43releasably couples the first surface44of the screw head50to a breakaway tab45;

In a step100of the method90, the non-threaded second portion30of the elongated stem11may be inserted into the hollow threaded channel64in the hinge66so that the non-threaded second portion30of the elongated stem11extends out of the hollow threaded channel64of the hinge66.

Alternatively, in the step102of the method90, the threaded first portion42of the elongated stem14may be inserted into the hollow threaded channel64in the hinge66by a user manipulating the insertion using the breakaway tab45.

In a step104of the method90, the threaded first portion20,42of the elongated stem11,14may be aligned with the threads63of the hollow threaded channel64of the hinge66.

In a step106of the method90, the first threaded portion20,42of the elongated stem11,14may be screwed into the hollow threaded channel64of the hinge66by rotating the threaded first portion20,42of the elongated stem11,14that has been aligned with the threads63of the threaded hollow channel64of the hinge66.

In one embodiment of the step102of the method90, the breakaway tab45extends along a longitudinal axis of the screw13, away from the first surface44of the screw head50.

In one embodiment of the step102of the method90, a first surface79of the breakaway tab84and a first surface80of the screw head86are coplanar, depicted inFIG. 5, and described in associated text.

In one embodiment of the step106of the method90, a user may turn the breakaway tab45about its longitudinal axis to rotate the screw13, wherein the breakaway tab45is releasably coupled to the first surface44of the screw head50by the second breakaway43.

In one embodiment of the step106of the method90, the breakaway tab45,84is broken off from the first surface44of the screw head50at the second breakaway43, or at the second breakaway83, after the threaded first portion42of the elongated stem14catches at least one thread63of the threaded hollow channel64of the hinge66.

In one embodiment of the step106of the method90, the non-threaded second portion30of the elongated stem11is broken off at the first breakaway25from the threaded first portion20of the elongated stem11after the threaded first portion20of the elongated stem is essentially completely screwed into the threaded hollow channel64of the hinge66.

In one embodiment of the step102of the method90, inserting the non-threaded second portion30of the elongated stem11into the hollow threaded channel64in the hinge66so that the non-threaded second portion30of the elongated stem11extends out of the hollow threaded channel64of the hinge66, by a user pulling the non-threaded second portion30of the elongated stem11.

In one embodiment of the step106of the method90, a user removes the non-threaded second portion30from the elongated stem11of the screw10after catching at least one thread63of the hollow threaded channel64of the hinge66.

one embodiment of the step106of the method90, the breakaway tab45extends along a longitudinal axis of the screw13, away from the first surface44of the screw head50when the breakaway tab45is broken off from the first surface44of the screw head50at the second breakaway43, after the threaded first portion42of the elongated stem14catches at least one thread63of the threaded hollow channel64of the hinge66.