Spiral Insert for Concealed Panel Fastening
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Solution Overview
Problem
Existing methods for attaching panels to back surfaces in building construction fail to hide fasteners effectively, often resulting in unsightly fixtures, weak fastening strength, and difficulties with panel distortion over time, especially when attempting to manufacture in large quantities or accommodate repeated attachment and detachment.
Innovation Solution
A spiral-shaped insert with radially inward arms and a snap connector that accommodates radial and perpendicular movement, allowing for secure attachment of panels without visible fasteners, manufactured from flexible materials like nylon or polycarbonate, enabling flexible bending and high connection strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fastener is used to attach a panel to a back surface, then the panel is securely attached, but the fastener becomes visible and unsightly
Solution Approach 1:
The fastening function is extracted from the visible panel surface and relocated to the reverse side. The insert is positioned in a cavity on the back surface of the panel, allowing the mounting screw to engage the insert without any visible fasteners on the front panel surface.
Solution Approach 2:
The insert is nested within a cavity in the panel's back surface. The mounting screw head-flange is nested between the insert's arms, creating a compact hidden fastening system where the fastening mechanism is contained within the panel thickness.
2Reliability
If a rigid fastening device is used on the reverse side of the panel, then the attachment is strong, but the device cannot accommodate panel distortion over time
Solution Approach 1:
The insert employs dynamic spiral arms that can flex and adjust their position. When the panel distorts or expands/contracts, the spiral arms rotate and flex to accommodate these changes while maintaining secure engagement with the mounting screw, preventing fastener failure.
Solution Approach 2:
The spiral arm geometry allows for parameter changes in the fastening system. The arms can change their angular position and radial distance from the center, enabling the insert to adapt to varying panel dimensions and distortion patterns while maintaining secure attachment.
3Adaptability or versatility
If a complex fastening device is designed to accommodate all movements, then it can handle distortion, but it becomes difficult to manufacture in large quantities
Solution Approach 1:
The insert is segmented into multiple independent spiral arms that can flex and rotate independently. This segmentation allows each arm to be a simple, standardized component that is easy to manufacture, while the collective arrangement provides complex movement accommodation capabilities.
Solution Approach 2:
The spiral arms are designed as thin, flexible structures that can bend and rotate to accommodate panel movements. These thin-walled flexible components are easily manufactured using processes like injection molding, enabling large-scale production while maintaining the flexibility needed to handle distortion.
4Object-generated harmful factors
If putty is used to hide a screw head, then the fastener is concealed, but the putty has different color and texture requiring an overcoat of paint
Solution Approach 1:
The fastening function is completely extracted from the visible panel surface, eliminating the need for cosmetic repairs like putty and paint. By positioning the entire fastening mechanism on the reverse side within a cavity, the panel front surface remains clean and requires no additional finishing steps.
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 solution provides a secure, long-lasting attachment that accommodates panel distortion and thermal stresses, allowing for repeated attachment and detachment while maintaining a sleek appearance, and can be efficiently manufactured in large quantities.
Implementation Method 1
Due to the/their spiral shape, the arms flex when a radial force is applied to the connector. Movement of connector in the radial direction is thereby accommodated.
Implementation Method 2
Due to the/their spiral shape, each arm flexes when a force perpendicular to the arm is applied to the connector. Movement of the connector in the direction perpendicular to the arm and rim is thereby accommodated.
Data Source
AI summary
Disclosed is an inset for a panel in the form of a pad or disk for holding supporting the weight of the panel and holding it against a back surface without any means of support for the panel being visible. The insert comprises; one or more spiral shape arms which spiral(s) radially inwards from a perimetral rim inwards toward the center of the insert where the arms have a connector to connect to mounting screw, bolt or rivet. Also disclosed is a panel wall assembly covering a back surface with a panel, comprising: the panel held face to face with the back surface by an out-of-sight insert inset in the panel; a mounting screw/bolt/rivet with a head-flange which protrudes from the back surface; and the insert comprising a connector connected to the head-flange of the mounting screw, bolt or rivet.