Self-Drilling Anchor with Segmented Threading for Drywall

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Solution Overview

Problem

Existing drywall anchors face challenges in securely fastening to friable materials like drywall and semi-rigid materials such as hollow doors, often resulting in blistering, reduced holding strength, and failure due to inability to penetrate support members effectively.

Innovation Solution

A self-drilling anchor with a unique threading structure, including a high-threading portion for drywall engagement and a smaller thread height for support member penetration, along with a distal portion for drilling through both drywall and support members, minimizing blistering and enhancing holding strength.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If high threading with large crest diameter is used to increase holding strength in drywall, then holding strength is improved, but drywall blistering occurs due to displacement of drywall material

Engineering Contradiction:

Improveholding strengthVSAvoiddrywall blistering

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The anchor employs different thread configurations for different functions: high threading with large crest diameter in the proximal portion for drywall engagement to maximize holding strength, and smaller threading in the distal portion for support member penetration. This local differentiation allows each section to optimize its specific function without causing adverse effects.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The anchor body is divided into distinct portions with different threading characteristics. The proximal portion has high threading for drywall grip, while the distal portion has smaller threading for penetrating support members. This segmentation allows the anchor to perform multiple functions with different thread geometries, preventing blistering while maintaining holding strength.

Inventive Principle:

Principle #1Segmentation

2Reliability

If large head diameter is used to prevent anchor from being driven through drywall, then anchor retention is improved, but drywall displacement and blistering are caused

Engineering Contradiction:

Improveanchor retentionVSAvoiddrywall displacement

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The anchor head diameter is reduced to smaller than the outer diameter of the high threading crest diameter. This parameter change prevents the head from displacing drywall material during installation, eliminating blistering while the threading configuration ensures the anchor remains retained in the drywall without being driven through.

Inventive Principle:

Principle #35Parameter changes

3Strength

If self-drilling anchor is used to penetrate support members, then holding strength is improved, but anchor may break due to torsion or spin in place causing drywall stripping

Engineering Contradiction:

Improveholding strengthVSAvoidanchor failure resistance

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The distal portion of the anchor features smaller threading with reduced thread height specifically designed for penetrating support members. This local differentiation allows the distal portion to engage the support member without excessive torsion that would cause breaking, while the proximal portion maintains high threading for drywall holding strength.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The anchor is segmented into proximal and distal portions with different threading characteristics. The distal portion's smaller threading reduces torsional stress during support member penetration, preventing anchor breakage, while the proximal portion's high threading ensures adequate holding strength in the drywall.

Inventive Principle:

Principle #1Segmentation

4Strength

If high thread height is used to provide high pullout strength in drywall, then holding strength is improved, but difficulty in penetrating support members increases

Engineering Contradiction:

Improvepullout strengthVSAvoidsupport member penetration

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The anchor employs high thread height in the proximal portion for maximum pullout strength in drywall, while the distal portion uses smaller thread height to reduce resistance during support member penetration. This local quality differentiation allows the anchor to achieve high holding strength without sacrificing ease of installation.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The threading is segmented into proximal and distal portions with different thread heights. The proximal portion's high thread height provides pullout strength, while the distal portion's smaller thread height facilitates easier penetration into support members, resolving the contradiction between holding strength and installation ease.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS8057147B2Self-drilling anchor

Publication Date: 2011.11.15 ILLINOIS TOOL WORKS INC

AI summary

A self-drilling anchor for use in a friable material or a semi-rigid material comprises a body having an axis, an axial bore adapted to receive a fastener, a proximal end, a drilling end, a proximal portion adjacent the proximal end having high threading having a crest diameter for engaging the friable or semi-rigid material, and a drilling portion adjacent the drilling end, an additional thread proximate the proximal end, the additional thread continuing between turns of the high threading, and a head at the proximal end having an outer diameter that is smaller than the crest diameter. The anchor additional thread is configured to engage either the friable material or, additionally, to firmly engage the semi-rigid material.