Hidden Fastener Spacer Block for Secure Grooved Board Installation
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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 or confined spaces.
Innovation Solution
A fastener unit with a spacer block, grip element, and resilient compression elements that fit within grooves to securely engage boards, allowing for self-installation without additional hands and accommodating various groove heights and joist configurations through fracturable joints and adjustable dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If hidden fastener systems use loose-fitting plates with fixed-thickness flanges, then installation is simplified, but the flanges cannot forcibly engage grooves to prevent board movement during expansion and contraction
Solution Approach 1:
The fastener system transitions from static fixed-thickness flanges to dynamic adjustable-thickness flanges that can be modified during installation. The flanges include adjustable elements (such as shims or sliding mechanisms) that allow the thickness to be varied to match different groove depths, enabling forcible engagement while maintaining ease of installation through a simple adjustment process rather than complex alignment procedures
Solution Approach 2:
The flange thickness parameter is made variable rather than fixed. The fastener system allows adjustment of the flange thickness parameter to match the specific groove depth in different board configurations, transforming a one-size-fits-all approach into an adaptable solution that maintains both ease of operation and reliable board securing across various installation scenarios
2Ease of manufacture
If hidden fastener systems use fixed-thickness flanges, then manufacturing is simplified, but the flanges cannot accommodate varying groove heights in different board configurations
Solution Approach 1:
The flange is divided into multiple segments or layers that can be independently adjusted. Instead of a single fixed-thickness piece, the flange consists of stackable or adjustable segments that can be configured to match different groove depths, allowing the fastener to accommodate varying groove heights while maintaining relatively simple manufacturing of individual segments
Solution Approach 2:
The flange thickness transitions from a fixed static dimension to a dynamic adjustable dimension. The fastener system incorporates mechanisms (such as adjustable shims, sliding plates, or telescoping elements) that allow the flange thickness to be modified in the field to match different groove heights, providing versatility without requiring completely different fastener designs for each board type
3Manufacturing precision
If hidden fastener systems require manual alignment of plates with grooves, then precise positioning is achieved, but installation becomes cumbersome requiring additional hands
Solution Approach 1:
The fastener system incorporates self-aligning features such as tapered leading edges, cam mechanisms, or elastic elements that automatically guide the flanges into proper alignment with the grooves during insertion. This self-service alignment mechanism eliminates the need for manual positioning by additional hands while maintaining precise plate-to-groove alignment through the inherent geometry or mechanical action of the self-aligning features
Solution Approach 2:
The fastener design includes preliminary alignment features built into the structure, such as pre-formed guide slots, tapered insertion paths, or pre-compressed elastic elements that automatically position the flanges correctly as they engage the grooves. This preliminary action of built-in alignment features ensures precise positioning occurs automatically during installation without requiring manual intervention for alignment
4Ease of manufacture
If hidden fastener systems use standard base heights, then manufacturing is simplified, but the flanges may not fit well in or align with grooves of varying depths
Solution Approach 1:
The fastener system employs a universal base design that can accommodate multiple groove depths through adjustable flange mechanisms. The base serves multiple functions: providing structural support, anchoring the fastener to the joist, and serving as a platform for the adjustable flanges. This multi-functionality allows a single base design to work with various board and groove configurations, maintaining manufacturing simplicity while achieving precise flange-to-groove fit through the adjustable flange components
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, aesthetically pleasing, and safe attachment of boards to joists, preventing movement during temperature changes and accommodating complex support structures, while allowing for easy installation and adjustment to fit different applications.
Implementation Method 1
a first resilient compression element extending from a first lateral side of the spacer block... the first resilient compression element being vertically compressible so that portions of it can be compressed from an open mode to a compressed mode
Implementation Method 2
a fracturable joint joining the first resilient compression element to the spacer block... the fracturable joint can be broken to adjust a height of the first resilient compression element
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.