Method of making self-drilling anchor

Abstract

A method of making a self drilling anchor for use in a friable material mounted on a member comprising an elongated body having an axis, an axial bore adapted to receive an elongated fastener, a flared end having torque transmitting surfaces therein, a proximal portion, an intermediate portion, a distal portion, and a drilling tip generally opposite the flared end, wherein the proximal portion has a threaded exterior having a root, a crest diameter, and a thread height, the intermediate portion has a threaded exterior having a root, a crest diameter substantially smaller than the crest diameter of the proximal portion, and a thread height substantially smaller than the thread height of the proximal portion, and the distal portion has a threaded exterior with a root that tapers toward the drilling tip, a crest diameter substantially smaller than the crest diameter of the proximal portion, and a thread height substantially smaller than the thread height of the proximal portion.

Description

[0001] This application is a division of U.S. patent application Ser. No. 10 / 844,706, filed on May 12, 2004.BACKGROUND OF THE INVENTION [0002] 1. Field of the Invention [0003] The present invention is directed to a method of making an anchor for use in a friable material, particularly to a self-drilling anchor to be used in drywall mounted to a member. [0004] 2. Description of the Related Art [0005] Because drywall is a friable material, mounting articles thereto can be difficult. In the past, at least three methods have been used. For light weight articles, small plastic expansion anchors have been used. These expansion anchors have typically required three steps to install: first, a hole is drilled into the drywall; second, the anchor insert is driven into the drilled hole; and finally, a threaded fastener is advanced into the anchor, spreading the anchor into engagement with the drywall. However, expansion anchors can typically hold light loads only. [0006] For heavy duty applica...

AI Technical Summary

Benefits of technology

The anchor provides enhanced pullout strength and resistance to torsional forces, allowing for successful installation in drywall and support members without spinning or stripping, while accommodating varying fastener lengths and reducing installation torque.

Problems solved by technology

Because drywall is a friable material, mounting articles thereto can be difficult.

However, expansion anchors can typically hold light loads only.

While toggle bolts have been effective, they are also generally expensive because they involve parts which must move relative to one another.

Toggle bolts also have been known to be difficult to install.

However, in most cases the drywall is mounted to wood support members, or studs, that are unseen by the user, and typically the location of these support members are unknown and unchecked by the user.

When a user of a typical self-drilling fastener attempts to install the anchor in drywall at a location of a support member, the anchor is unable to drill into the support member, causing the anchor to spin in place so that the anchor's high threading strips out the drywall, resulting in failure of the anchor and creating an unsightly scar on the wall.

Even if the anchor is able to drill into the support member slightly, the anchors have been known to tightly engage the support member and break due to torsion on the anchor.

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