Decking Plug Strip for Concealing Fastener Holes Without Waste
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current decking systems using man-made or composite materials face challenges in concealing fastener holes without generating waste and maintaining a consistent aesthetic, as existing solutions require discarding parts of the decking plank to fill holes.
Innovation Solution
A plug apparatus comprising a support strip with connected plugs, where each plug is designed to break off upon insertion into a fastener hole, and injection-molded monolithic plugs that match the texture and color of the decking planks to create a seamless appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If plugs are formed from decking planks by cutting holes, then the aesthetic consistency is maintained, but material waste increases
Solution Approach 1:
The patent applies this principle by using separate plugs made from recycled or lower-cost materials to fill fastener holes, rather than discarding portions of expensive decking planks. The plugs serve their temporary purpose of concealing holes and can be replaced if needed, while the main decking material is fully utilized.
Solution Approach 2:
The patent recovers material by using sawdust, wood chips, or other wood byproducts from plank manufacturing to create the plugs. This transforms waste materials into useful components that maintain aesthetic consistency while eliminating the need to discard portions of finished planks.
2Ease of operation
If multiple separate plug components are used, then ease of installation improves, but device complexity increases
Solution Approach 1:
The patent merges multiple plug components into a single integrated apparatus where multiple plugs are attached to a common support member. This allows installers to handle and install multiple plugs simultaneously as one unit, reducing the number of separate handling operations while maintaining the simplicity of individual plug insertion.
Solution Approach 2:
The patent segments the plug apparatus into modular components (multiple plugs attached to a support member) that can be easily separated and installed individually. Each plug remains a simple, standalone component that can be inserted into its corresponding hole, while the support member facilitates efficient distribution and installation of multiple plugs.
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 solution effectively conceals fastener holes while minimizing material waste and maintaining the aesthetic integrity of the decking system, allowing for a seamless transition between planks and plugs.
Implementation Method 1
injecting a hot fluidic composition into the mold cavity to fill the mold cavity; allowing the fluidic composition to cool
Implementation Method 2
allowing the fluidic composition to cool
Implementation Method 3
a textured side of the insert forms a roof of the at least one plug chamber; the formed plug having a top surface comprising a texture pattern corresponding to a texture pattern of the textured side of the insert
Data Source
AI summary
A decking system including a plank and a plug that is configured for insertion into fastener holes of the plank to conceal the fastener holes. The plug may be formed as part of a plug apparatus which may be an injection molded monolithic structure including a support member and a plurality of the plugs coupled thereto. The support member may be a support strip that extends along a strip axis. The plurality of plugs may be connected to the support strip. Each of the plugs may be configured to be detached from the support strip and inserted into a fastener hole in a plank. The plugs may include a first set of the plugs located on a first lateral side of the support strip and a second set of the plugs located on a second lateral side of the support strip opposite the first lateral side.