Hidden Deck Board Fastener for Self-Aligning Groove Retention
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Solution Overview
Problem
Existing hidden fastener systems for securing grooved boards to underlying support structures are inadequate as they fail to forcibly engage the boards with the joists, leading to movement during temperature changes and require manual alignment, and are not suitable for double or triple joist configurations.
Innovation Solution
A fastener unit with a spacer block, grip element, and resilient compression elements that fit within the groove of the board, allowing for self-alignment and secure engagement without additional hands, and can be adapted for various groove sizes and joist configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If hidden fastener systems use loose-fitting plates with horizontal flanges, then the boards can be concealed from view, but the boards cannot be forcibly engaged to prevent movement during expansion and contraction
Solution Approach 1:
The fastener system uses resilient compression elements that can dynamically adjust to groove height variations while maintaining engagement force. The elements compress during installation and then resiliently expand to provide continuous engagement pressure, adapting to thermal expansion and contraction of the boards without losing reliability.
Solution Approach 2:
The patent changes the physical state of the engagement elements from rigid to resilient/compressible. This parameter change allows the fastener to maintain reliable engagement across varying groove heights and board dimensions, solving both the concealment requirement and the engagement strength requirement simultaneously.
2Manufacturing precision
If manual alignment is required during installation, then precise positioning can be achieved, but installation time and complexity increase
Solution Approach 1:
The fastener system is designed to self-align within the groove through its own structural features. The resilient compression elements and grip elements automatically position themselves correctly when inserted into the groove, eliminating the need for manual alignment while maintaining precise positioning and high installation speed.
Solution Approach 2:
The patent replaces the manual mechanical alignment process with an automatic self-aligning mechanism. The geometry of the grip elements and their interaction with the groove surfaces provides automatic positioning, substituting human operator actions with inherent mechanical guidance features.
3Ease of manufacture
If fixed-thickness flanges are used, then manufacturing is simplified, but the fastener cannot adapt to different groove heights and configurations
Solution Approach 1:
The fastener system replaces fixed-thickness flanges with resilient compression elements that can dynamically adjust their compression level to match different groove heights. This dynamic adaptation maintains ease of manufacture while providing versatility across various groove configurations.
Solution Approach 2:
The patent changes the thickness parameter of the engagement elements from fixed to variable through the use of compressible materials. This allows the same manufactured component to adapt to different groove heights by varying its compression state rather than requiring different fixed-thickness components.
4Device complexity
If standard fastener sizes are used, then inventory management is simplified, but the fastener cannot fit in confined spaces or accommodate double/triple joist configurations
Solution Approach 1:
The fastener system is segmented into modular components including the spacer block, resilient compression elements, and grip elements. This segmentation allows different combinations and configurations of the same basic components to accommodate various joist arrangements, maintaining simple inventory management while providing adaptability to double or triple joist configurations.
Solution Approach 2:
The patent designs the fastener components to serve multiple functions and configurations. The same grip element and compression element design can accommodate single, double, or triple joist configurations by adjusting their positioning and engagement, providing universal applicability across different structural arrangements.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The fastener unit provides secure and concealed attachment of boards to joists, preventing movement due to temperature changes and allowing for easy installation of multiple units, even in confined spaces, with the resilient compression elements ensuring firm hold and adaptability to different groove heights.
Implementation Method 1
a first resilient compression element extending from a first lateral side of the spacer block and vertically compressible to fit within the groove of the board, and a second resilient compression element extending from a second lateral side of the spacer block and vertically compressible to fit within the groove of the board
Data Source
AI summary
A fastener unit and related method for securing a board to a support is provided. The fastener unit includes a spacer block, a grip element extending from the spacer block and configured to fit in and engage a groove of the board, and one or more board engagement elements. The board engagement elements can engage the groove of the board, thereby securing the spacer block in a position adjacent the groove to establish a gap between the board and another board. Related methods of use also are provided.