Torque transmission driver

1. A torque transmission driver adapted to fit a recess in a fastener of less than 0.06 inches major dimension comprising:

a torque transmission driver having a mean torque to failure value, a drive axis and a main body with a first end portion and a second end portion,

the first end portion adapted to receive and transmit torque from a torque generating source to the driver,

the second end portion opposite the first end portion having a key shape with side walls and a protruding lead end,

the key shape adapted to fit a recess in a fastener and having a major dimension of less than 0.06 inches and a minor dimension,

the protruding lead end defined by a major dimension and a minor dimension, the major dimension tapering at a taper angle between 10° and 30° from a plane perpendicular to the drive axis of the driver with at least a portion of the protruding lead end initiating at the major dimension of the key shape, the minor dimension of the protruding lead end being equal to the minor dimension of the key shape for a transition portion of the protruding lead end and merging with the major diameter of the protruding lead end for a remainder portion of the protruding lead end, such that the protruding lead end is shaped to match the recess in the fastener such that torque can be transmitted from the second portion of the main body to the fastener through the protruding lead end, and

wherein the mean torque to failure value has a standard deviation, and that standard deviation is less than approximately 7% of the mean torque to failure value.

2. The torque transmission driver as set forth in claim 1 wherein the protruding lead end of the second end portion of the main body has a taper angle between 15° and 25°.

3. The torque transmission driver as set forth in claim 2 where the protruding lead end of the second end portion of the main body has a taper between 18° and 22°.

4. The torque transmission driver as set forth in claim 1 wherein the protruding lead end of the second end portion of the main body is magnetized.

5. The torque transmission driver as set forth in claim 1 wherein the key shape in the second end portion of the main body has a shape selected from the group consisting of a quadrasplinular, pentasplinular, hexasplinular, quadralobular, pentalobular, hexalobular, hexagonal, pentagonal, Bristol and polydrive.

6. The torque transmission driver as set forth in claim 1 wherein the protruding lead end has a taper adapted to match a portion of the recess in the fastener.

7. The torque transmission driver as set forth in claim 1 wherein the transition portion of the protruding lead end extends from adjacent the key shape to an intersection of the major dimension of the protruding lead end and minor dimension of the protruding lead end.

8. A torque transmission driver adapted to drive a small fastener having a recess with a major dimension less than 0.1 inches comprising:

a torque transmission driver having a mean torque to failure value, a drive axis and a main body with a first end portion and a second end portion,

the first end portion adapted to receive and transmit torque from a torque generating source to the driver,

the second end portion opposite the first end portion having a key shape with parallel side walls and a protruding lead end, the key shape adapted to fit a recess in a fastener and having a major dimension of less than 0.1 inches and a constant minor dimension,

the protruding lead end defined by a major dimension and a minor dimension, the major dimension tapering at a taper angle between 10° and 30° from a plane perpendicular to the drive axis of the driver with at least a portion of the protruding lead end initiating at the major dimension of the key shape, the minor dimension of the protruding lead end being equal to the constant minor dimension of the key shape for a transition portion of the protruding lead end and merging with the major diameter of the protruding lead end for a remainder portion of the protruding lead end, such that the protruding lead end is a rounded cone shaped to match the recess in the fastener such that torque can be transmitted from the second portion of the main body to the fastener through the protruding lead end which is frictionally engaged with a majority of a lower portion of the recess, and

wherein the mean torque to failure value has a standard deviation, and that standard deviation is less than approximately 7% of the mean torque to failure value.

9. The torque transmission driver adapted to drive a small fastener as set forth in claim 8 wherein the protruding lead end of the second end portion of the main body has a taper angle between 15° and 25°.

10. The torque transmission driver adapted to drive a small fastener as set forth in claim 9 where the protruding lead end of the second end portion of the main body has a taper between 18° and 22°.

11. The torque transmission driver adapted to drive a small fastener as set forth in claim 8 wherein the protruding lead end of the second end portion of the main body is magnetized.

12. The torque transmission driver adapted to drive a small fastener as set forth in claim 8 wherein the key shape in the second end portion of the main body has a shape selected from the group consisting of quadrasplinular, pentasplinular, hexasplinular, quadralobular, pentalobular, hexalobular, hexagonal, pentagonal, Bristol and polydrive.

13. The torque transmission driver adapted to drive a small fastener as set forth in claim 8 wherein the key shape of the second end portion of the main body is adapted to fit a recess having a major dimension of up to 0.060 inch in the fastener.

14. The torque transmission driver adapted to drive a small fastener as set forth in claim 8 wherein the key shape of the second end portion of the main body is adapted to fit a recess having a major dimension of up to 0.040 inch in the fastener.

15. The torque transmission driver as set forth in claim 8 wherein the protruding lead end has a taper adapted to match a portion of the recess in the fastener.

16. The torque transmission driver as set forth in claim 8 wherein the transition portion of the protruding lead end extends from adjacent the key shape to an intersection of the major dimension of the protruding lead end and minor dimension of the protruding lead end.

17. A torque transmission driver comprising:

a main body with a first end portion, a mean torque to failure value, and a second end portion, the main body having a drive axis,

the first end portion adapted to receive torque from a torque generating source to rotate the main body around the drive axis,

the second end portion opposite the first end portion, wherein the second end portion has a key shape portion and a protruding lead end extending from the key shape portion to an end of the main body opposite the first end portion;

the key shape portion having a pentalobular cross-section with side walls parallel to the drive axis, defining a key shape with a major diameter of less than 0.06 inches and a minor diameter,

the protruding lead end having a transition portion adjacent the key shape portion and a remainder portion extending from the transition portion to the end of the main body opposite the first end portion,

the transition portion defining a tapering pentalobular shape with a major diameter initiating at the major dimension of the key shape and tapering towards the end of the main body at a taper angle between 10° and 30° from a plane perpendicular to the drive axis of the driver, and a minor diameter equal to the minor diameter of the key shape, such that a side wall of the key shape having the minor diameter extends continuously through the transition portion,

the transition portion extending from adjacent the key shape portion to an intersection of the major diameter of the transition portion with the minor diameter of the transition portion,

the remainder portion of the protruding lead end extending from the intersection at the taper angle to the end of the main body opposite the first end portion, and wherein the end of the main body opposite the first end portion contains a rounded tip, and

wherein the mean torque to failure value has a standard deviation, and that standard deviation is less than approximately 7% of the mean torque to failure value.