Hidden Beam Connection Bracket for Fast Channel-Based Assembly
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Solution Overview
Problem
The assembly of solid elongated wooden or plastic beams requires complex channels and unsightly fastening methods like nails and screws, which are inefficient and aesthetically unappealing for structures like decks and furniture.
Innovation Solution
A structural support apparatus featuring a connection bracket with a flat, rigid member and extending arm and finger that fit into complementary hollow channels in attachable members, allowing for secure attachment without visible fasteners, using materials like metal, wood, or composite materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If complex channels are bored within beams and nails/screws are inserted to fasten beams, then beams can be attached to support beams, but the assembly becomes aesthetically unappealing and requires complex manufacturing
Solution Approach 1:
The connection bracket is divided into distinct functional segments: a body portion that attaches to the support beam, an arm that receives the channel, and a finger that engages with the beam. This segmentation allows each component to be optimized independently, simplifying manufacturing while achieving secure attachment without complex integrated channels.
Solution Approach 2:
The connection bracket serves as an intermediary component between the support beam and the attachable member. Instead of directly boring complex channels into the beam itself, the bracket mediates the connection by receiving the simple channel and engaging the beam through its finger, thereby simplifying the channel design while maintaining attachment strength.
2Ease of operation
If nails, tacks, screws are inserted through top surfaces of beams to fasten beams, then beams can be attached to support beams, but the fastening becomes visible and aesthetically unappealing
Solution Approach 1:
The visible fastening elements (nails, screws, tacks) are extracted from the beam's top surface and relocated to the connection bracket, which attaches to the underside of the beam. The bracket's finger receives the channel and engages the beam from below, completely hiding the attachment mechanism from view while maintaining secure fastening.
Solution Approach 2:
Instead of inserting fasteners through the top surface of the beam as in conventional methods, the connection bracket engages the beam from the underside. The finger of the bracket receives the channel and secures the beam from below, inverting the traditional fastening direction to achieve aesthetic concealment.
3Productivity
If traditional fastening methods are used with visible nails and screws, then beam attachment is straightforward, but assembly time increases and productivity decreases
Solution Approach 1:
The hollow channel is pre-formed within the attachable member during manufacturing, before assembly. This preliminary action eliminates the need for on-site drilling or complex fastening operations, allowing the bracket to simply slide into the pre-formed channel and secure the beam, dramatically reducing assembly time and increasing productivity.
Data Source
AI summary
A structural support apparatus comprises a connection bracket comprising, a generally flat, rigid member having opposing generally flat faces and a thickness extending between the flat faces. The rigid member is attachable to a support member. An arm extends from an end of the rigid member and a finger extends from the arm and is receivable in a hollow channel formed in an attachable member of rigid material. The hollow channel is complementary in configuration to at least one of the finger and the arm and a selected recess configuration is formed between the finger, the arm and the end of the rigid member. The recess accommodates one or more lip portions of the attachable member when either the arm or the finger, are received within the hollow channel.