Sealing Washer with Self-Aligning Adapter for Building Envelope
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Solution Overview
Problem
In building construction, fasteners can create leak paths for moisture, causing damage by securing through inner wall members, which are not effectively sealed against air and water infiltration.
Innovation Solution
A washer and fastener combination with a central aperture, prong members, and sealing surfaces that self-retain on soft building materials, allowing for secure fastening without manual handling and providing a sealing mechanism against moisture and air ingress, using an adapter system for precise alignment with a fastener gun.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If fasteners are used to secure barrier sheets through inner wall members, then the barrier sheets are firmly attached to the wall, but moisture and air can infiltrate through the fastener holes creating leak paths
Solution Approach 1:
A washer is introduced as an intermediary component between the fastener and the barrier sheet. The washer includes a sealing surface that contacts the barrier sheet to prevent moisture and air infiltration through the fastener hole, while the fastener secures the washer to the wall through the barrier sheet.
Solution Approach 2:
The sealing surface of the washer is designed to conform to the barrier sheet, creating a flexible seal that prevents infiltration. The washer material and geometry allow it to adapt to the barrier sheet surface while maintaining the seal under fastener loading.
2Manufacturing precision
If manual handling of washers is required during installation, then precise placement can be achieved, but installation time and labor increase
Solution Approach 1:
The washer is designed with self-aligning features including an alignment surface that interfaces with the fastener gun nose stem. This allows the washer to automatically position itself relative to the fastener hole during automated installation, eliminating the need for manual placement while maintaining precision.
Solution Approach 2:
The washer incorporates multiple functions: it provides sealing against moisture and air infiltration, serves as a mounting surface for the barrier sheet, and includes alignment features for automated fastener gun installation. This multi-functionality enables both precision and productivity.
3Productivity
If automated fastener guns are used for installation, then installation speed increases, but precise alignment with the washer aperture becomes difficult
Solution Approach 1:
An adapter is introduced as an intermediary component that couples the fastener gun to the washer. The adapter includes a receptacle that receives the washer and an arm that attaches to the fastener gun, with alignment features that ensure precise positioning of the fastener relative to the washer aperture during automated installation.
Solution Approach 2:
The alignment surface on the washer and corresponding features on the adapter create a self-aligning mechanism. When the adapter is attached to the fastener gun and positioned on the washer, the alignment features automatically guide the fastener into correct alignment with the washer aperture, enabling precise automated installation.
4Ease of manufacture
If the washer design is simplified for easy manufacturing, then production cost decreases, but sealing effectiveness and alignment capability are compromised
Solution Approach 1:
The washer is designed with different geometries in different regions to optimize local functions. The outer periphery includes a sealing surface for moisture prevention, the center includes an aperture for fastener passage, and the inner region includes an alignment surface for fastener gun positioning. Each region is shaped to perform its specific function effectively.
Solution Approach 2:
The washer incorporates multiple functional features (sealing surface, aperture, alignment surface) in a single integrated component. This allows the simple washer geometry to provide sealing, fastener attachment, and alignment capabilities simultaneously, maintaining reliability while keeping the overall design simple for manufacturing.
Data Source
AI summary
A washer and fastener combination for use in building construction includes a fastener having a cylindrical shaft, with a threaded end defining one end and a head defining another end, and includes a plastic washer. The washer includes a bottom side and an upper side defining a solid outer surface, and an aperture extending through the washer. A cavity is formed in the upper side at the aperture that defines an opening in the upper side, with the opening defined by the cavity being larger than an opening defined by the aperture whereby the cavity includes a seat that is disposed about the aperture and is recessed from the upper side. The fastener further includes one of either a flange or a secondary washer at the head, with the shaft of the fastener configured for insertion into the aperture with the flange or secondary washer recessed within the cavity.