Self-Boring Wallboard Anchor With Split-Tip Pull-Out Resistance
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Solution Overview
Problem
Existing wall anchors for drywall and other friable wallboards face challenges in manufacturability and performance, particularly in efficiently penetrating the wallboard without pre-drilling and providing reliable retention against pull-out.
Innovation Solution
The development of an elongated anchor body with a driving end, a wall boring end featuring axially cutting teeth, a wall seating flange with a thread, and diametrically opposed recesses and slots, which allows for easy installation by cutting a bore into the wall and providing additional retention through thread engagement and potential anchor splitting when a fastener is inserted.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If an anchor is designed to penetrate wallboard without pre-drilling, then installation ease is improved, but the complexity of the anchor structure increases to achieve effective penetration and retention
Solution Approach 1:
The patent combines multiple functions into a single integrated anchor body: the penetration function (cutting teeth at the tip), the retention function (threads along the body), and the expansion function (splitting mechanism triggered by fastener insertion). This merging allows the anchor to achieve effective wallboard penetration and secure retention without pre-drilling, while managing structural complexity through functional integration rather than separate components
Solution Approach 2:
The anchor incorporates pre-formed cutting teeth at the tip and pre-configured splitting geometry (diametrically opposed recesses and slots) that are prepared in advance. When the fastener is inserted, it automatically triggers the splitting action without requiring additional steps or complex mechanisms. This preliminary preparation enables the anchor to penetrate and secure itself through simple insertion, improving installation ease while controlling complexity
2Reliability
If the anchor body includes multiple features (cutting teeth, threads, recesses, slots), then retention performance is improved, but manufacturability becomes more challenging
Solution Approach 1:
The anchor body is segmented into distinct functional zones: a tip region with cutting teeth for penetration, a middle section with threads for retention, and diametrically opposed recesses with slots for the splitting mechanism. This segmentation allows each feature to be optimized independently for its specific function while being manufactured as an integrated piece, balancing retention performance with manufacturability through modular functional design
Solution Approach 2:
The patent optimizes geometric parameters of each feature to achieve reliable performance: the cutting teeth have specific angles and dimensions for effective cutting, the threads have optimized pitch and depth for secure engagement, and the recesses/slots have precise geometry for controlled splitting. These parameter optimizations ensure high retention performance while maintaining compatibility with standard manufacturing processes for plastic extrusion or injection molding
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
The anchor effectively penetrates the wallboard, creates a secure thread path for retention, and enhances pull-out resistance through the splitting mechanism, improving both manufacturability and performance by simplifying the installation process and ensuring strong attachment.
Implementation Method 1
The wall boring end includes a plurality of axially cutting extending teeth, wherein each cutting tooth includes a forward cutting edge and a radial cutting edge
Implementation Method 2
the main body portion includes a thread that runs from an intermediate location along a length of the main body portion and toward the wall seating flange
Implementation Method 3
The internal bore includes a first bore section running from the driving end toward the distal tip and a second bore section running from the first bore section toward the distal tip. The second bore section has a smaller size in axial end view than the first bore section, such that a fastener threaded into the bore causes and end section of the anchor body to split when the fastener pushes radially outwardly on inner wall portions of the second bore section
Data Source
AI summary
An anchor for wallboard installation includes an elongated anchor body including a driving end and a wall boring end. The anchor body has a main body portion running from the driving end toward the wall boring end. The wall boring end includes a plurality of axially cutting extending teeth. The anchor body includes an internal bore and diametrically opposed slots to facilitate split of an end portion of the anchor body when the anchor is installed in a wall and a fastener is inserted for mounting an object.