Masonry Panel Fastener Insert with Transformable End
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Solution Overview
Problem
Conventional masonry panel installation methods require skilled labor, are prone to delamination and moisture-related decay, and have labor-intensive insert installation processes, with potential for screw over-tightening and panel damage.
Innovation Solution
A masonry panel design featuring a fastener insert with a transformable end and a tube channel, secured by an engagement end with ribs, allowing for automated installation and improved moisture resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional mortar installation method is used, then panels can be adhered to building walls, but skilled labor is required and risk of delamination and moisture decay increases
Solution Approach 1:
The patent replaces the chemical mortar bonding system with a mechanical fastening system using embedded inserts and screws. The inserts are molded directly into the panel during manufacturing, providing precise mechanical attachment points that eliminate the need for skilled mortar application while ensuring reliable panel-to-substrate attachment.
Solution Approach 2:
The fastener inserts are pre-installed in the mold during panel manufacturing, positioning fastening points before the panel is even installed. This preliminary action eliminates the need for on-site insert installation and ensures proper positioning without requiring skilled labor during installation.
2Reliability
If embedded inserts are used for fastening, then installation reliability improves, but insert installation becomes labor intensive and difficult to automate
Solution Approach 1:
The patent merges the insert installation process with the panel manufacturing process itself. Inserts are placed in the mold and become an integrated part of the panel during the molding process, eliminating the separate, labor-intensive step of installing inserts after panel fabrication and enabling full automation.
Solution Approach 2:
The inserts are pre-positioned in the mold during panel manufacturing, performing the fastening preparation action before the panel is completed. This eliminates the need for subsequent manual insert installation and allows for fully automated panel installation processes.
3Strength
If screws are driven through embedded inserts, then secure attachment is achieved, but screws may be over-tightened breaking the panel
Solution Approach 1:
The patent incorporates a deformable seal portion in the insert that acts as a cushioning element. As the screw is driven in, this portion deforms to absorb excess force and prevent over-tightening damage to the panel, while still maintaining secure attachment and sealing the screw head.
Solution Approach 2:
The insert material properties are designed to change under screw driving force - the seal portion transitions from a rigid support structure to a deformable cushioning element. This parameter change allows the same structure to provide both strong attachment and protection against over-tightening.
4Strength
If substantial contact between panel and surface is used, then attachment area increases, but moisture retention and decay risk increases
Solution Approach 1:
The patent extracts the sealing function from the attachment system by incorporating a dedicated seal portion within the insert. This separate sealing element prevents moisture ingress at the fastener penetration point while maintaining substantial contact area between the panel back and substrate for structural attachment.
Solution Approach 2:
The insert is segmented into distinct functional portions: a rigid engagement portion for mechanical attachment and a deformable seal portion for moisture prevention. This segmentation allows each portion to optimize its specific function while working together to provide both strong attachment and moisture protection.
Data Source
Figure 1
Figure 2
Figure 2a
AI summary
The present invention relates to a masonry panel for installation on a surface with the panel comprising a front-side surface and a back-side surface with the front-side surface including at least one mortar joint on the front-side surface. The masonry panel also comprises at least one fastener insert positioned within the at least one mortar joint with the at least one fastener insert comprising a transformable end to cover a fastener head once the fastener head has passed through the transformable end and a rigid tube connected to the transformable end allowing the fastener to travel through the panel.