Cast-In-Place Anchor Structure With Reduced Metal and Stable Setting
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Solution Overview
Problem
Existing cast-in-place anchors, such as the Wood-Knocker II+ product, face inefficiencies in securing loads to wooden form boards due to excessive metal usage and movement issues when concrete sets, leading to increased manufacturing costs and potential instability.
Innovation Solution
A cast-in-place anchor system comprising plastic body sections with a metallic washer and threaded nut, where the washer is in direct contact with concrete, preventing movement and reducing metal volume, allowing for secure load support with reduced manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional cast-in-place anchors use extensive metal components, then strength and load-bearing capacity are improved, but manufacturing cost increases and metal usage becomes excessive
Solution Approach 1:
The anchor is divided into distinct functional components: a plastic body section that provides structural form and positioning, and a separate metallic threaded insert that provides load-bearing capacity. This segmentation allows each material to be used only where necessary, reducing overall metal usage while maintaining strength.
Solution Approach 2:
Metal is applied locally only where load-bearing function is required (the threaded insert), rather than using metal throughout the entire anchor structure. The plastic body sections provide form and positioning functions where metal would be unnecessary, achieving material optimization.
2Reliability
If concrete sets around traditional anchors, then anchoring is achieved, but movement and instability occur during the setting process
Solution Approach 1:
The plastic body sections and metallic threaded insert are pre-assembled into a stable configuration before concrete setting. The threaded insert is securely positioned within the plastic body, ensuring proper alignment and preventing movement during the concrete setting process. This preliminary assembly eliminates instability that would occur with loose components.
3Strength
If more metal is used in anchor construction, then strength is improved, but manufacturing cost increases
Solution Approach 1:
The anchor uses a composite construction combining plastic body sections with a metallic threaded insert. This composite approach allows the use of inexpensive plastic for the structural body while incorporating metal only where strength is critical (the threaded portion), thereby reducing overall material cost while maintaining anchor strength.
Solution Approach 2:
The plastic body sections serve as a cost-effective alternative to entirely metal construction. Plastic is a cheaper material that suffices for the body portions not requiring load-bearing capacity, reducing manufacturing costs while the essential metal threaded insert provides the necessary strength.
Data Source
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AI summary
A cast-in-place anchor and method of securing it to a wooden form board. Such a cast-in-place anchor comprising: a body defining a cavity and having a base for positioning the body on a wooden form board, the body being configured to be secured to the wooden form board by at least one fixing member; an opening in the base of the body in communication with the cavity; a plurality of additional openings in the body in communication with the cavity; a threaded member provided in the cavity; a support member also provided in the cavity for supporting the threaded member and for restricting the ingress of wet concrete through the additional openings into contact with the threaded member in use; wherein the anchor is configured such that after concrete pouring, concrete setting and form board removal in use a threaded rod can be inserted into the opening in the base of the body, past the support member and into threaded engagement with the threaded member for suspending a load from the anchor.