L-Channel Lock Fasteners for Tool-Less Wood Substrate Joining
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Solution Overview
Problem
Existing fastening systems for wood substrates are prone to damage during routing and drilling, often result in misaligned joints, and are cumbersome to install, especially for novice assemblers, and do not allow for flat-packing during shipment.
Innovation Solution
A fastening device with channel locks that can be adjusted from 15 to 165 degrees, featuring recessed channels and t-slot routs that allow for secure connection without the need for edge boring, enabling easy alignment and installation without tools, and accommodating various substrate sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If routing and drilling on the edge of wood substrates, then fasteners can be installed to connect substrates, but the substrates are damaged and joints become misaligned
Solution Approach 1:
Routs are pre-formed into the substrates at specific locations and angles before assembly. These routs provide predetermined pathways for the fasteners, eliminating the need for edge routing and drilling during assembly, thus preventing substrate damage while enabling secure fastener installation
Solution Approach 2:
The fastener acts as an intermediary component that connects substrates through pre-formed routs rather than requiring direct edge fastening. This intermediary mechanism allows substrates to be joined without compromising their structural integrity or requiring damaging edge modifications
2Strength
If using screws or staples with angle brackets to attach substrates, then substrates can be connected, but the installation process becomes cumbersome and requires multiple tools
Solution Approach 1:
The fastener integrates multiple functions into a single component: it provides alignment features for precise positioning, connection features for securing substrates, and structural support for joint strength. This unified design eliminates the need for separate angle brackets, alignment tools, and multiple fastening operations
Solution Approach 2:
The fastener incorporates self-aligning features such as guide slots and positioning elements that automatically align with the pre-formed routs during insertion. This self-alignment mechanism eliminates the need for manual alignment by the installer, making the process simple and tool-less while maintaining strong joint connections
3Ease of operation
If drilling holes on the edge of substrate, then fasteners can be installed, but the wood substrates are damaged
Solution Approach 1:
Routs are pre-formed into the substrates at specific locations and angles before assembly. These routs provide predetermined pathways for the fasteners, eliminating the need for edge routing and drilling during assembly, thus preventing substrate damage while enabling secure fastener installation
Solution Approach 2:
Instead of creating holes from the edge of the substrate (one-dimensional approach), the solution uses pre-formed routs that extend into the substrate surface (two-dimensional approach). This dimensional change allows fasteners to be inserted at angles that avoid edge damage while maintaining secure anchorage within the substrate
4Manufacturing precision
If using angle brackets to align substrates, then substrates can be properly aligned, but the process is extremely difficult for novice assemblers
Solution Approach 1:
The fastener incorporates self-aligning features such as guide slots and positioning elements that automatically align with the pre-formed routs during insertion. This self-alignment mechanism eliminates the need for manual alignment by the installer, making the process simple and tool-less while maintaining strong joint connections
Solution Approach 2:
The fastener features asymmetric geometry with specific guide slots and engagement surfaces that are designed to fit only one orientation with the pre-formed routs. This asymmetric design provides built-in alignment guidance, ensuring correct orientation and positioning without requiring the installer to perform complex alignment operations
5Strength
If using traditional fastening methods, then substrates can be connected, but manufacturing time is high
Solution Approach 1:
Routs are pre-formed into the substrates during manufacturing before assembly. This preliminary action eliminates the need for time-consuming alignment operations, edge routing, and sequential fastening steps during assembly, significantly reducing manufacturing time while maintaining strong joint connections through the integrated fastener design
Solution Approach 2:
The fastening system is segmented into independent components: pre-formed routs in substrates and modular fasteners with specific engagement features. This segmentation allows for parallel processing during manufacturing and rapid assembly by simply inserting fasteners into the pre-prepared routs, eliminating sequential operations and reducing overall manufacturing time
Data Source
AI summary
A fastening device, a fastening system comprising a fastening device and corresponding slots/routs are described. There is a fastening device having at least two sides. In another embodiment the fastening device has three sides. Two of the three sides are about ninety degrees to each other and each of the two sides have a fastener located on its outer surface. There is one corresponding slot for each fastener. Each corresponding slot is on the surface of two separate substrates and located approximately ten millimeters away from an outermost edge of the substrate. The fastener secures with the corresponding slot, consequently joining the two substrates at approximately ninety degrees.