Embedded Fastener Assembly for Gypsum Panel Installation
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Solution Overview
Problem
Conventional building surface products are time-consuming to install and require specialized skills for finishing, making them inefficient for rapid installation and aesthetically pleasing results.
Innovation Solution
A building surface product featuring a substantially planar panel with an embedded fastener assembly, including a threaded embedded fastener with a lateral projection and a linking fastener that secures the panel to a support structure without exposing the fasteners, allowing for quick installation and hidden fastening system, enabling faster installation and aesthetic finishes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional gypsum panels are mounted using mechanical fasteners and finished with joint compound and paint, then the building surface achieves structural attachment and aesthetic appearance, but the installation process becomes time-consuming and requires specialized skills
Solution Approach 1:
The fasteners are pre-embedded into the gypsum panel during manufacturing, creating a pre-assembled unit that combines the panel and attachment hardware into a single integrated component ready for immediate installation
Solution Approach 2:
The patent combines the gypsum panel, fasteners, and finishing surface into a single integrated prefabricated assembly, merging multiple separate installation steps into one simultaneous operation
2Strength
If mechanical fasteners are used to attach gypsum panels to supporting structures, then the panels achieve secure mounting, but the fasteners and joints require subsequent covering to create a smooth surface
Solution Approach 1:
The patent extracts the fasteners from the visible surface plane and positions them within recesses or channels on the panel surface, removing the need for additional covering materials while maintaining secure attachment
3Shape
If multiple finishing steps are applied to cover joints and fasteners, then the building surface achieves a smooth and aesthetically pleasing appearance, but the process requires uncommon skills and multiple drying cycles
Solution Approach 1:
The panel surface is self-finishing through its inherent design features such as integrated fastener recesses, pre-applied coatings, or textured surfaces that naturally conceal fasteners without requiring additional joint compound or paint applications
Data Source
AI summary
A building surface product includes a panel having a front surface, a rear surface, a first side, a second side, a first end, a second end, and a gypsum body between the front surface and rear surface. A first hole extends through the gypsum body and includes a front end and a rear end. A first fastener assembly is positioned in the first hole. The first fastener assembly includes an embedded fastener and a linking fastener. The embedded fastener has a threaded body that extends through the first hole of the gypsum body and has a front end a rear end, and a lateral projection disposed at the front end of the threaded body. The linking fastener includes a threaded body that engages the threaded body of the embedded fastener. The linking fastener extends outward from the rear end of the first hole. The first fastener assembly is contained behind the front surface of the panel.