Channel Strut Fastener Block for Multi-Standard Hardware Fit
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Solution Overview
Problem
Existing fastener systems for channel strut framing are limited in accommodating both standard SAE and metric hardware, requiring separate specialized fasteners for different sized nuts and bolts, and struggle to securely position fasteners within the channel without movement during installation.
Innovation Solution
A fastener block with multiple receptacles of varying sizes on its upper and lower surfaces, along with threaded apertures, allows for the secure engagement and rotation within the strut channel, using malleable protrusions and deflectable tabs to maintain position and prevent movement, and can be made from non-conductive materials to prevent corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple specialized fasteners are used to accommodate different sized nuts and bolts, then compatibility with various hardware standards is improved, but device complexity increases
Solution Approach 1:
The fastener block is designed with multiple receptacles of different sizes on its upper and lower surfaces, allowing a single fastener block to accommodate various sized nuts and bolts (SAE and metric standards). This multi-functional design eliminates the need for multiple specialized fasteners while maintaining compatibility with different hardware standards.
Solution Approach 2:
The fastener block is segmented into multiple receptacles of varying sizes, each capable of receiving different fastener types. This segmentation allows the single fastener block to serve multiple functions by providing dedicated spaces for different sized nuts and bolts, thereby reducing the overall number of fastener types needed in the system.
2Ease of operation
If standard fasteners are used without positioning mechanisms, then ease of installation is improved, but fastener stability deteriorates due to movement during installation
Solution Approach 1:
The fastener block includes positioning mechanisms (malleable protrusions and deflectable tabs) that are pre-configured to engage with the strut channel walls. These mechanisms perform the positioning action automatically when the fastener block is inserted, preventing movement during installation before the final fastening operation occurs.
Solution Approach 2:
The positioning mechanisms act as intermediaries between the fastener block and the strut channel walls. The malleable protrusions and deflectable tabs engage with the channel walls to provide lateral support and prevent movement, thereby stabilizing the fastener block during the installation process without complicating the overall installation procedure.
3Strength
If metal fasteners are used for structural strength, then strength is improved, but galvanic corrosion occurs when contacting dissimilar metals in the channel strut
Solution Approach 1:
The fastener block serves as an intermediary component between the metal fasteners (nuts and bolts) and the channel strut. By positioning the fasteners within its receptacles and securing them laterally, the fastener block prevents direct contact between dissimilar metals, thereby eliminating galvanic corrosion while maintaining structural strength through proper fastener engagement.
Solution Approach 2:
The system is segmented into distinct functional components: the fastener block provides isolation and positioning, while the metal fasteners provide structural strength. This segmentation allows each component to perform its optimal function without causing harmful interactions, specifically preventing galvanic corrosion by separating the dissimilar metal contact surfaces.
Data Source
AI summary
Provided herein is a fastener that may be used to secure objects to a channel strut or attach a channel strut to a structure. In an arrangement, the fastener is a fastener block configured for disposition within the interior of a channel strut. The fastener block has a body with an embedded reinforcing member. At least one aperture extends through the body of the fastener block between upper and lower surfaces. A fastener receptacle may be formed around the aperture. A standard nut or bolt may be inserted into the fastener receptacle.