Deck-Mounted Faucet Installation to Prevent Plywood Loosening
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Deck mounted faucets often become loose due to swelling and contraction of plywood decks caused by water exposure, necessitating frequent replacements.
Innovation Solution
An installation plug system is used to create a recessed region in the deck, allowing plumbing fixtures to be mounted to a waterproofing layer instead of the plywood, using a backing plate and PVC components to ensure secure installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the faucet is directly mounted to the plywood deck, then the installation is simple, but the faucet becomes loose due to plywood swelling and contraction from water exposure
Solution Approach 1:
The patent introduces a mounting plate as an intermediary component between the faucet and the plywood deck. This mounting plate is attached to the deck at multiple spaced-apart locations, creating a stable interface that isolates the faucet from the plywood's dimensional changes due to moisture. The faucet then mounts to this stable plate rather than directly to the expanding/contracting wood.
Solution Approach 2:
The mounting system is segmented into distinct functional components: the mounting plate that interfaces with the deck, the fastening mechanism that secures the plate to the deck at multiple locations, and the faucet mounting interface. This segmentation allows each component to perform its specific function independently, with the mounting plate absorbing the dimensional changes while providing a stable mounting surface.
2Adaptability or versatility
If the plywood deck is exposed to water, then the deck performs its intended function in a wet environment, but the plywood swells and contracts causing fixtures to become loose
Solution Approach 1:
The mounting plate serves as a mediator between the wet environment and the faucet fixture. It remains attached to the plywood deck at multiple spaced locations, allowing the deck to expand and contract while the plate maintains its structural integrity and provides a stable mounting surface for the faucet.
Solution Approach 2:
The system anticipates the dimensional changes in plywood due to moisture exposure by using multiple spaced fastening locations. This distribution of attachment points cushions against the swelling and contracting forces, preventing any single fastener from bearing excessive stress that would cause loosening.
Data Source
AI summary
A method for installing deck mounted plumbing fixtures. At least one annular opening is created in a horizontal planar deck. A backing plate is attached to the deck bottom and an installation plug is placed through the opening in the deck so that it rests on the backing plate. The installation plug includes an annular disc and a cylindrical post. A planar member is applied over the deck top surface, the planar member including at least a layer of liquid material. The liquid material is allowed to harden, and the backing plate and the installation plug are removed, thus creating an opening in the planar member. A plumbing fixture is then installed in the opening in the planar member, such that the plumbing fixture is affixed to the top and bottom surface of the planar member and not to the deck.