Modular Adhesive Anchor Screen With Adjustable Shutters
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Solution Overview
Problem
Current apertured sleeves for adhesive construction anchors are expensive, have limited length and aperture size options, and require multiple components, making them inefficient for various adhesive types and substrates, especially when dealing with hollow substrates like concrete blocks and masonry units.
Innovation Solution
A modular adhesive insert and screen system with adjustable shutters and apertures, allowing multiple screens to be connected for varying sizes and adhesive compatibility, using injection molding for cost-effective production and adaptable to different adhesive viscosities and particle sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional apertured sleeves are used to retain adhesive, then adhesive containment is improved, but device complexity and manufacturing cost increase due to multiple components and assembly processes
Solution Approach 1:
The patent combines the sleeve body, apertures, and shutters into a single integrated component. The shutter mechanism is built into the sleeve structure itself, eliminating the need for separate retention devices or assembly steps. This merging maintains adhesive containment functionality while reducing device complexity and manufacturing cost.
Solution Approach 2:
The sleeve is designed to perform multiple functions: containing adhesive, controlling flow through apertures, and managing shutter operations. This multi-functionality eliminates the need for multiple separate components, thereby reducing device complexity while maintaining reliable adhesive containment.
2Ease of manufacture
If fixed aperture sizes are used in apertured sleeves, then manufacturing is simplified, but adaptability to different adhesive types and viscosities deteriorates
Solution Approach 1:
The patent incorporates movable shutters that can dynamically adjust the aperture openings based on adhesive properties. The shutters respond to adhesive viscosity and flow characteristics, automatically optimizing the effective aperture size. This dynamic adjustment maintains ease of manufacture with fixed physical apertures while achieving adaptability to different adhesive types.
Solution Approach 2:
The shutter mechanism changes the effective aperture parameter (opening size) based on adhesive characteristics. By varying the shutter position, the system adapts to different adhesive viscosities and flow rates, maintaining manufacturing simplicity while achieving versatility across adhesive types.
3Quantity of substance
If adhesive is allowed to flow freely in hollow substrates, then complete adhesive distribution is improved, but adhesive loss into voids increases
Solution Approach 1:
The shutter mechanism provides localized control over adhesive flow at different positions along the sleeve. Shutters can be positioned to allow adhesive flow only in regions where substrate material is present, preventing adhesive from flowing into hollow voids. This local control ensures complete adhesive distribution in needed areas while minimizing waste in voids.
Solution Approach 2:
The shutter system responds to local conditions (presence of substrate material vs. voids) by adjusting adhesive flow. When the shutter detects or responds to void conditions, it closes to prevent adhesive flow; when substrate is detected, it opens to allow distribution. This feedback mechanism optimizes adhesive distribution while preventing loss into voids.
4Ease of manufacture
If limited length screens are used, then manufacturing cost is reduced, but productivity decreases due to multiple assemblies for longer applications
Solution Approach 1:
The patent designs the sleeve as a modular component that can be easily connected to form longer assemblies. The segmentation allows standard-length sleeves to be manufactured cost-effectively while enabling flexible combination for various application lengths, thereby maintaining both manufacturing efficiency and installation productivity.
Solution Approach 2:
The sleeves are pre-manufactured in standard lengths with connection features ready for assembly. This preliminary preparation enables quick field assembly for longer applications without requiring custom manufacturing, thus maintaining low production costs while improving installation productivity through rapid modular assembly.
Data Source
AI summary
A modular adhesive insert for a construction anchor allows for controlled dispersion of adhesive in a pre-formed bore, and multiple insert screens to be attached to each other to create many sizes of screens. The insert comprises an end cap and also includes an abutment structure. The insert includes a housing with a first end and a second end, the first end including a first set of connection structures, the second end including a second set of connection structures, the housing including a plurality of shutters between the first end and the second end, each of the shutters adapted to vary a size of an opening associated with each said shutter.