Gypsum Board Expansion Anchor With Tearable Support-Foot Strap
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Solution Overview
Problem
Conventional expansion screw anchors for gypsum boards often fail due to excessive twisting force causing the support feet to separate unexpectedly, preventing proper fixation, and require additional anchors or modifications to function effectively.
Innovation Solution
An expansion screw structure with a thin coupling strap connecting the support feet, which supports reverse twisting forces and prevents separation, allowing the anchor to be securely screwed into the gypsum board by tearing the strap and expanding the support feet when a screw is inserted.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the connection portion is made long to prevent unexpected separation of support feet, then the reliability of drilling into gypsum board improves, but the ability to expand support feet when screw is inserted deteriorates
Solution Approach 1:
The connection portion has non-uniform thickness with a thin portion (1-3mm) and a thick portion (5-10mm). The thin portion is positioned to break first during expansion, allowing support feet to separate, while the thick portion remains intact to maintain structural integrity during drilling operations.
Solution Approach 2:
The connection portion is segmented into functional zones with different thicknesses. The thin portion serves as a sacrificial element that breaks during expansion, while the thick portion serves as a structural element that maintains strength during drilling, creating distinct functional segments within a single component.
2Stability of the object's composition
If the support feet are made strong to resist twisting force, then the stability during drilling improves, but the ability to separate and expand when screw is inserted deteriorates
Solution Approach 1:
The support feet have non-uniform thickness distribution with thicker regions for stability during drilling and thinner connection portions for controlled separation. This local variation in thickness creates different mechanical properties in different regions of the same component.
Solution Approach 2:
The anchor combines material properties of strength and flexibility through strategic thickness variation. The thicker portions provide rigidity and strength for drilling stability, while the thinner portions provide flexibility and controllability for separation during expansion.
3Reliability
If the connection portion is made thick to support twisting force, then the reliability of maintaining connection improves, but the ability to break and expand support feet deteriorates
Solution Approach 1:
The connection portion has non-uniform thickness with a thin portion (1-3mm) positioned to break first during expansion, while a thick portion (5-10mm) is positioned to maintain structural integrity during drilling. This local variation in thickness creates different mechanical properties in different regions.
Solution Approach 2:
The connection portion is segmented into functional zones with different thicknesses that serve different purposes: the thin portion serves as a sacrificial element for expansion, while the thick portion serves as a structural element for drilling stability.
Data Source
AI summary
An expansion screw structure contains an anchor for mating with a screw. The anchor includes a first segment and a second segment which have a central axis, and a shank. The anchor further includes a head which has a slot. The shank includes a first threaded section, multiple cutouts, a decreasingly conical tip, a second threaded section, a slit, a first support foot, a second support foot. The slit has a first part, a second part, and a third part. The second part has a first raised portion, the second part has a second raised portion, and the third part has a connection section and a thin coupling strap. The thin coupling strap has a first thickness, the connection section has a second thickness, and the first thickness of the coupling strap is ⅓ of the second thickness of the connection section.