Hollow Anchor Thread Forming Split Die
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Solution Overview
Problem
Existing self-tapping, threaded masonry anchors face challenges in accurately forming self-tapping outer threads, which are critical for a strong connection with masonry substrates, and require separate operations for forming internal and external threads, leading to inefficiencies and potential inconsistencies in thread formation.
Innovation Solution
A method using a multi-part split die and mandrel to plastically deform a hollow blank, forming a radial helical thread on the outer surface of the anchor in a non-cutting operation, allowing for precise and efficient production of hollow anchors with an internal cavity and a raised external contour suitable for tapping threads in masonry, while also forming a driving tool fitting portion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate operations are used to form internal and external threads (cold forming draw process for internal thread, rolling pin for external thread), then the anchor can be manufactured with both internal and external threads, but the manufacturing process becomes complex and thread formation consistency deteriorates
Solution Approach 1:
The patent combines the formation of internal and external threads into a single integrated operation using a multi-part split die system. The die simultaneously forms both the internal driving portion and the external radial thread on the hollow blank in one process step, eliminating the need for separate cold forming draw and rolling pin operations. This merging of operations reduces manufacturing complexity while maintaining thread formation consistency.
Solution Approach 2:
The die is divided into multiple parts (split die with multiple segments) that can be assembled and disassembled. This segmentation allows the die to perform multiple functions (forming both internal and external threads) while maintaining simplicity in each individual component. The segmented structure enables easy maintenance and replacement without requiring complete die replacement.
2Manufacturing precision
If separate operations are used to form internal and external threads, then each thread can be formed by specialized processes, but production efficiency deteriorates due to multiple steps
Solution Approach 1:
The multi-part split die combines internal and external thread formation into a single simultaneous operation, eliminating multiple production steps. This merging maintains manufacturing precision because the die is designed with precise tolerances for both thread types, while dramatically improving productivity by forming both threads in one process cycle rather than requiring sequential operations.
3Reliability
If traditional separate formation processes are used, then internal and external threads can be formed independently, but installation efficiency deteriorates due to production complexity
Solution Approach 1:
The integrated die system produces anchors with consistent and reliable thread formation by forming both internal and external threads in a single controlled operation. This eliminates variability introduced by multiple separate processes, ensuring reliable connection strength. The simplified production process also improves ease of operation by reducing manufacturing complexity and ensuring uniform product quality across production batches.
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
This method enables the production of high-quality, self-tapping masonry anchors with uniform thread dimensions and tolerances, ensuring strong connections with masonry substrates and reducing production complexity, thereby improving installation efficiency and anchor reliability.
Implementation Method 1
the outer surface of the blank being plastically deformed by the action of radial forces generated by a mandrel inserted through the hollow blank
Data Source
AI summary
A method of and device for manufacturing a hollow anchor with a radial, helical contour on its outer surface is provided. The contour is preferably a raised external contour or helix that is formed on the outer wall of the anchor and is suitable for tapping a thread in masonry. The hollow anchor formed by the method has an internal cavity that can receive another member and an outer surface with a raised external contour that is suitable for tapping a thread in a blind bore in a masonry member.