Nested Channel Swivel Anchor for Drywall Load Distribution
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Solution Overview
Problem
Existing anchors for drywall structures are limited in supporting heavy, non-static loads due to the material's poor structural strength and the constraints of insertion aperture size and depth, leading to weak points in hinged or flexible designs that restrict the anchor's holding strength.
Innovation Solution
A heavy-duty anchor with a minimally sized configuration that expands in multiple directions, utilizing nested metal channel elements with a rotational expansion mechanism to increase the holding interface with the substrate, allowing for load distribution across the insertion aperture and resistance to shear and tensile forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If hollow wall expansion anchors with hinged or flexible structures are used, then the anchor can be inserted through a pre-drilled hole and expanded behind the wall, but the hinge portions and soft metal create weak points that limit holding strength
Solution Approach 1:
The anchor is divided into multiple rigid channel elements (first channel element, second channel element, etc.) that can be independently positioned and secured. Each channel element is a separate rigid component rather than a single flexible piece, eliminating weak hinge points while maintaining the ability to expand behind the wall.
Solution Approach 2:
The channel elements are nested within each other during insertion, with the first channel element inserted through the hole, followed by the second channel element nested within or alongside it. This nested configuration allows compact insertion through the pre-drilled hole while enabling expansion to multiple channel elements behind the wall.
2Strength
If larger anchors are used to increase holding strength, then the anchor can support heavier loads, but the insertion aperture size must be increased which weakens the drywall
Solution Approach 1:
The multiple channel elements are nested within each other during insertion, allowing the anchor assembly to pass through a relatively small pre-drilled hole in a compact configuration. Once behind the wall, the elements are positioned and expanded to provide large holding surface area without requiring a large insertion aperture.
Solution Approach 2:
The anchor transitions from a compact one-dimensional insertion profile to a multi-dimensional expanded configuration behind the wall. The channel elements are positioned in different orientations and planes, creating a three-dimensional holding structure that maximizes wall contact area while minimizing the two-dimensional insertion hole size.
3Length of stationary object
If the available depth behind drywall is limited to 9.53cm, then the hollow space is constrained, but this limits the size and length of anchors that can be placed behind the wall
Solution Approach 1:
Instead of extending a single long anchor element through the limited 9.53cm depth, the invention uses multiple shorter channel elements positioned in different orientations and planes. This multi-dimensional arrangement provides equivalent or superior holding capability within the constrained depth by distributing the holding function across multiple elements in space.
Solution Approach 2:
The anchor function is segmented into multiple channel elements of appropriate lengths that can be individually positioned within the available depth. Each channel element can be optimized for its specific function and positioned to maximize wall contact within the 9.53cm constraint, rather than requiring a single long element.
4Reliability
If non-static heavy items such as hospital railings are supported on drywall, then patient safety requires high holding strength, but drywall has poor structural strength and crumbles when disrupted
Solution Approach 1:
The load from heavy non-static items is distributed across multiple rigid channel elements that are positioned in different orientations behind the wall. This segmentation of the holding function prevents concentration of stress on a single point, reducing the likelihood of drywall crumbling while maintaining high overall holding strength for safety-critical applications.
Data Source
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Figure 4A~4C
Figure 5A~5C
AI summary
A method and an anchor for supporting items on a substrate such as drywall. The anchor comprises a structure configured to carry the anchoring element in a minimal cross section configuration through an insertion hole and to effect a first expansion. The anchor further comprises an adjustable cap member configured to be moved to fixedly position the anchoring element to the non-accessible side of the substrate. The anchoring element comprises a base channel member, a top channel member, and a connector-pivoting element configured to pivotally connect the top channel member to the base channel member. The top channel member is configured to be nested with the base channel member in the minimal cross section configuration and to be pivotally rotatable via the connector pivoting element in the plane parallel to the non-accessible side of the wall, with the pivotal rotation of the top channel member providing the second expansion.