Wall Hanger Suspension Washer Design to Reduce Installation Error
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Solution Overview
Problem
Existing wall hanger systems for attaching furniture to vertical walls are prone to human error during installation, including incorrect screw selection and depth, leading to improper engagement and potential instability of the attached items.
Innovation Solution
A wall hanger system featuring a suspension washer with a mounting face and a slotted suspension fitting, allowing for adjustable attachment to the wall and item, ensuring correct positioning of the slot engagement edge within the suspension slot, regardless of screw type or depth, thereby reducing installation errors and enhancing stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a simple screw attachment system is used, then the device complexity is reduced, but the reliability of proper engagement deteriorates due to human error in screw selection and depth
Solution Approach 1:
The suspension washer acts as an intermediary component between the screw and the suspension fitting. It provides a standardized interface that mediates the connection, ensuring reliable engagement regardless of screw variations. The washer's mounting face and slot engagement edge create a consistent geometric relationship that guarantees proper positioning.
Solution Approach 2:
The invention changes the parameter of engagement geometry by providing a standardized slot engagement edge position on the washer. This parameter change ensures that the suspension fitting always engages at the correct depth and orientation, eliminating variability caused by different screw depths and types.
2Adaptability or versatility
If adjustable mounting is provided, then the adaptability to different wall materials and screw types is improved, but the device complexity increases due to the washer design
Solution Approach 1:
The suspension washer is designed as a universal component that works with various screw types and wall materials. Its mounting face provides a standardized attachment interface, while the slot engagement edge provides a standardized suspension interface, making the system adaptable without requiring complex variations in the washer design.
Solution Approach 2:
The washer design segments the mounting function from the suspension function. The mounting face handles attachment to the wall, while the slot engagement edge handles engagement with the suspension fitting. This segmentation allows each part to be optimized independently while maintaining overall simplicity.
3Manufacturing precision
If the slot engagement edge is positioned at a fixed distance from the abutment plane, then the manufacturing precision of engagement is improved, but the ease of operation deteriorates due to reduced adjustment flexibility
Solution Approach 1:
The system provides dynamic adjustment capability through the keyhole slot geometry. The suspension fitting can be inserted at various positions along the slot, allowing operational adjustment, but when engaged, the geometry ensures precise positioning at the correct depth. This combines manufacturing precision with operational flexibility.
Data Source
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AI summary
A wall hanger system for attaching an item to be hung to a vertical wall, comprises a suspension washer (28) configured to be attached to one of the wall and the item (14a) to be hung, the suspension washer (28) comprising a mounting face (32) configured to abut, along an abutment plane, said one of the wall and the item (14a) to be hung, and a slot engagement edge (34) separated from, and facing, said abutment plane; and a slotted suspension fitting (30) for cooperation with said suspension washer (28), the slotted suspension fitting (30) being configured to be attached to the other of the wall and the item (14a) to be hung and comprising a suspension slot (46) having a first, relatively wider, washer insertion portion configured to freely receive the slot engagement edge (34) of the suspension washer (28), and a second, relatively narrower, washer engagement portion configured to engage with the slot engagement edge (34) of the suspension washer (28).