Deck Ledger Spacer With Keyed Bushing and Sealant Wells
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Solution Overview
Problem
Existing deck ledger spacers lack versatility in accommodating various fastener sizes and types, and do not effectively integrate with sealants or adhesives to enhance structural integrity and prevent water intrusion.
Innovation Solution
A deck spacer with a centrally located keyed bushing system for accommodating different fastener diameters, conical and cylindrical countersinks for secondary fasteners, and sealant wells to constrain adhesives, allowing for a wide range of fastener compatibility and increased structural strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single fixed-size hole is used in the spacer, then the structure is simple, but it cannot accommodate various fastener diameters
Solution Approach 1:
The spacer incorporates a keyed bushing system with multiple diameters that can be selectively installed to accommodate different fastener sizes (structural screws, lag screws, bolts). The keyed design allows the bushing to be precisely positioned and secured in the spacer's recess, enabling a single spacer type to serve multiple fastener compatibility requirements.
Solution Approach 2:
The fastener accommodation function is segmented into separate keyed bushings that can be independently selected and installed in the spacer. Each bushing is a discrete component with a specific diameter, allowing the system to be configured for different fastener types without redesigning the entire spacer.
2Strength
If traditional fastening methods are used, then installation is straightforward, but structural integrity is insufficient
Solution Approach 1:
The spacer design nests multiple functional features within its structure: sealant wells are recessed into the spacer body, countersink recesses are integrated to receive fastener heads, and keyed bushings are positioned within central recesses. This nested arrangement allows multiple fastening and sealing functions to be combined in a single component without significantly increasing overall complexity.
3Object-affected harmful factors
If spacers without sealant integration are used, then manufacturing is simpler, but water intrusion prevention is inadequate
Solution Approach 1:
The spacer merges the sealing function directly into its structural design by incorporating sealant wells as integral recesses. These wells are formed as part of the spacer body, allowing sealant to be applied directly during installation. This combination of structural and sealing functions eliminates the need for separate sealing components and reduces overall system complexity.
Data Source
AI summary
A deck ledger board spacer system that includes a solid disc body having a front side and a rear side, a center hole, and a plurality of circumferential through holes surrounding the center hole. The center hole includes at least one radially-extending void that serves as a female element for a complementary keyed bushing. Each of the front and rear sides have a plurality of wells recessed from the disc body surface, the wells configured to receive a volume of flowable adhesive sealant material during spacer installation. One or more swappable keyed bushings are sized for insertion in the center hole, each of the keyed bushings having a male element complementary to the radially-extending void and having a bushing through hole with a diameter different from other keyed bushings in a plurality of keyed bushings.