Interlocking Construction Packer Assembly for Stable Shim Stacking

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Solution Overview

Problem

Existing building packers often slip askew when stacked, requiring additional fastening steps to maintain alignment, which can be inconvenient or impractical in certain situations.

Innovation Solution

A construction packer with a base part and stacking shim featuring interlocking features, such as slots and detents, that securely engage to form a unitary assembly without the need for screws, allowing for easy handling and alignment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If multiple packers are stacked one on top of the other to obtain the correct wedge thickness, then the desired packing thickness is achieved, but the packers do not always remain aligned or can slip askew as they are inserted into position

Engineering Contradiction:

Improvepacking thickness precisionVSAvoidpacker alignment stability

Core Design Contradiction:

Manufacturing precisionVSStability of the object's composition

Solution Approach 1:

The packer system is divided into multiple segments (individual packers of different thicknesses) that can be stacked to achieve the desired total thickness. Each segment maintains its structural integrity while allowing combination with others through the interlocking features.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The packers are designed to be nested within each other during stacking, with each packer fitting securely on top of the previous one through the interlocking features, creating a stable stacked configuration similar to nested dolls.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Stability of the object's composition

If fastening holes are aligned to fasten stacked packers in position, then the packers remain aligned and stable, but the process requires an extra step of fastening which may not be convenient or necessary

Engineering Contradiction:

Improvepacker alignment stabilityVSAvoidoperation convenience

Core Design Contradiction:

Stability of the object's compositionVSEase of operation

Solution Approach 1:

The packers are designed with self-aligning and self-securing features that automatically maintain alignment and stability without requiring external fastening operations. The interlocking features perform the alignment and securing functions inherently during the stacking process.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The alignment and securing functions are built into the packer design beforehand through the interlocking features, so that when packers are stacked, they automatically align and secure themselves without requiring preliminary or subsequent fastening actions.

Inventive Principle:

Principle #10Preliminary action

3Manufacturing precision

If multiple packers are stacked to achieve the desired packing thickness, then the correct wedge thickness is obtained, but the packers can slip askew during insertion requiring additional fastening steps

Engineering Contradiction:

Improvewedge thickness precisionVSAvoidtime for alignment and fastening

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The alignment and securing functions that would otherwise require separate operations are merged into a single stacking action through the interlocking features, allowing multiple packers to be combined into a stable assembly in one continuous motion without time-consuming alignment and fastening steps.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS12540477B2Construction packer

Publication Date: 2026.02.03 MCARTHUR JACOB WAJSMAN

AI summary

A construction packer comprising a base part including a base shim and a wall component extending substantially perpendicular to the base shim, the wall component having a first interlocking feature; and a stacking shim configured to be placed on top of the base shim and having a second interlocking feature provided at an edge thereof that engages with the first interlocking feature to provide an assembled construction packer.