Anchor Fastener With Frangible Shaft-Base Connection
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Solution Overview
Problem
Current drywall anchor installation methods for fixtures are time-consuming and prone to misalignment, requiring pre-measurement and separate installation of drywall anchors, which can lead to inaccuracies and safety hazards due to the need for multiple tools and ladder access.
Innovation Solution
An anchor fastener with a pre-assembled design featuring a frangible connection between the shaft and base, allowing for self-drilling and alignment directly to the mounting surface without prior anchor installation, using a helical thread and self-drilling tip to secure the fixture without separate drywall anchors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional separate drywall anchor installation method is used, then secure attachment to mounting surface is achieved, but installation time increases and misalignment occurs
Solution Approach 1:
The patent combines the drywall anchor and the fastener into a single integrated unit. The anchor body includes a shaft with threading and a base with engagement features, eliminating the need for separate anchor installation. This merging allows the fixture to be directly attached to the mounting surface through the integrated anchor-fastener unit, significantly reducing installation time and eliminating misalignment issues between separately installed anchors and fixture holes.
2Ease of operation
If multiple separate fastening components are used, then secure attachment is achieved, but device complexity and installation difficulty increase
Solution Approach 1:
The patent integrates multiple functions into a single anchor fastener unit: the shaft provides structural support and threading for wall engagement, the base provides engagement features for fixture attachment, and the frangible portion provides controlled separation capability. This consolidation reduces the number of components from multiple separate items (anchor, fastener, screws) to a single integrated unit, making installation simpler and reducing the risk of losing small components.
Solution Approach 2:
The anchor fastener is divided into distinct functional segments: the shaft portion for wall engagement, the base portion for fixture attachment, and the frangible portion for controlled separation. This segmentation allows each part to perform its specific function optimally while remaining part of an integrated unit that simplifies installation compared to completely separate components.
3Adaptability or versatility
If frangible connection is used between shaft and base, then controlled separation is enabled, but connection strength may be reduced
Solution Approach 1:
The frangible portion is designed with specific local qualities: it has reduced cross-sectional area or weakened material properties only at the separation interface, while the shaft and base portions maintain full strength for their respective functions. This localized weakness allows controlled separation when needed (providing installation flexibility) while maintaining adequate connection strength during normal operation and installation.
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
Streamlines the installation process by eliminating the need for pre-measuring and separate anchor installation, reducing misalignment and safety hazards, while ensuring secure attachment to the mounting surface without penetrating beyond the surface or hitting studs.
Implementation Method 1
The shaft (1514) includes a self-drilling tip (1828) configured to drill into the mounting surface (2100)
Implementation Method 2
The shaft (1514) includes a helical thread (1516) that extends along an outer surface of the shaft (1514) towards the distal end of the shaft (1514)
Implementation Method 3
at least one frangible portion (1822) configured to frangibly connect the shaft (1514) to the base (1520). The at least one frangible portion (1822) is separable from at least one of the base (1520) and the shaft (1514) under application of a force to the shaft (1514)
Implementation Method 4
The head (1512) includes a flexible portion (1912) configured to flex away from the base (1520) and in a direction perpendicular to the shaft (1514). The flexible portion (1912) is configured to engage the protrusion (1526) and flex to resist and slow rotation of the shaft (1514) during installation of the shaft (1514)
Data Source
AI summary
An anchor fastener is described. The anchor fastener includes a head, a generally cylindrical shaft extending from the head, a base at a distal end of the shaft, and at least one frangible portion configured to frangibly connect the shaft to the base. The shaft includes a helical thread that extends along an outer surface of the shaft towards the distal end of the shaft. The frangible portions are separable from the base and the shaft under application of a force to the shaft. The base includes a distal surface and an engagement portion configured to engage an object to be anchored to a mounting surface and configured to hold the anchor fastener to the object before installation of the shaft through the object and into the mounting surface. The base includes a thread guide configured to support the helical thread during installation of the shaft.