Drywall Holder Mount With Self-Drilling Anchor Alignment
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Solution Overview
Problem
Existing wall mountable holders are inadequate for friable substrates like drywall, as they often require pre-drilling, may weaken the holding strength, or rely on adhesive with low holding power, and struggle with proper fastener orientation during installation.
Innovation Solution
A substrate-mountable holder system featuring a first portion with a hook, lobe, pad, and detents, and a second portion with interfacing detents and a self-drilling drywall anchor, which ensures secure engagement and alignment without pre-drilling, enhancing pullout resistance and load capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a screw with small root and major diameters is used in an integrated holder, then the holder can be installed by rotating the entire holder, but the fastener may not be oriented properly and may require backing out or embedding non-threaded portion, potentially weakening holding strength or causing holder failure
Solution Approach 1:
The holder is divided into a base portion and a cover portion that can be assembled together. The base portion contains the fastener and mounting features, while the cover portion provides the visible housing. This segmentation allows the fastener to be pre-oriented and properly positioned in the base before final assembly, eliminating the need to back out or re-orient the fastener after installation.
Solution Approach 2:
The fastener is pre-installed and pre-oriented in the base portion during manufacturing, with its orientation and positioning predetermined. The base portion includes features such as recesses, channels, or detents that guide and secure the fastener in the correct orientation before the holder is installed on the wall. This preliminary action eliminates the need for post-installation adjustment.
2Strength
If holders are designed for rigid substrates like exposed studs, then they provide strong holding strength, but they perform poorly in friable substrates like drywall
Solution Approach 1:
The holder base portion is designed with universal mounting features that can accommodate different substrate types. It includes a self-drilling drywall anchor with a self-tapping fastener that can install in both friable substrates like drywall and semi-rigid substrates like hollow-core doors without requiring pre-drilling or adaptation. The base portion's design with recesses, channels, and detents provides consistent mounting performance across different substrate types.
3Strength
If threaded portions are made long enough to embed in studs, then holding strength increases, but pre-drilling is required which demands additional planning, tools and time
Solution Approach 1:
The base portion includes a self-drilling drywall anchor with a self-tapping fastener that creates its own pilot hole and threads during installation. The fastener automatically drills through the drywall and engages the anchor without requiring pre-drilling, positioning, or special tools. This self-service mechanism eliminates the need for additional planning, pilot hole preparation, or complex installation procedures while maintaining strong holding strength.
4Ease of operation
If adhesive backing is used to mount the holder, then installation is simplified, but holding strength is significantly less than mechanical fastening methods
Solution Approach 1:
The base portion includes a self-drilling drywall anchor that acts as an intermediary between the holder and the substrate. Instead of relying directly on adhesive to bond the holder to the wall, the anchor mechanically engages the substrate through self-drilling and self-tapping action, providing superior holding strength while maintaining relatively simple installation procedures.
Data Source
AI summary
A substrate-mountable holder system, comprising: a first portion comprising a base having first and second front surfaces, a rear surface, a top and a bottom, a hook extending from proximate the bottom, a lobe extending rearwardly from a rear surface proximate the top, a pad extending rearwardly from the rear surface, an opening for receiving an anchor extending through the base, the opening between the lobe and the pad; and a second portion for operatively engaging the first portion; wherein the first and second portions each include at least one, and preferably a plurality of, interfacing protrusions and indentations for engaging the second portion with the first portion. Each of the protrusions and indentations on the first and second portions may be proximate the bottom of their respective portions. The system further may include a self-drilling drywall anchor having a bore, and a fastener for operatively engaging the first portion and the bore.