Welded Expansion Anchor Length Customization to Cut Waste
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Solution Overview
Problem
Existing expansion anchors require different lengths to secure objects to concrete, leading to inefficiencies in inventory management, environmental waste, and unsightly protrusions.
Innovation Solution
A method of forming expansion anchors by welding a conical expansion part to a threaded rod of predetermined length, allowing for customization of anchor lengths on demand, thereby reducing inventory needs and environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If expansion anchors are stocked in multiple fixed lengths, then a range of objects can be secured to concrete, but inventory management becomes complex and waste increases
Solution Approach 1:
The expansion anchor system transitions from static fixed-length threaded rods to a dynamic configuration where the threaded rod length can be adjusted on-demand. The modular design allows the threaded rod to be detached and replaced with different lengths as needed, converting a static inventory system into a dynamic, adaptable one that reduces waste while maintaining versatility.
Solution Approach 2:
The expansion anchor is divided into separable components: the expansion sleeve with conical expansion element (remaining in concrete) and the threaded rod (removable). This segmentation allows the threaded rod to be replaced with different lengths based on specific application requirements, eliminating the need to stock complete anchor assemblies in multiple lengths and reducing inventory waste.
2Reliability
If threaded rod is too long, then sufficient embedment depth is achieved, but excess length protrudes causing safety and aesthetic issues
Solution Approach 1:
The threaded rod length becomes a dynamic parameter that can be adjusted to match the exact requirements of each application. By selecting or fabricating threaded rods of precise lengths, the system ensures adequate embedment depth while eliminating excess protrusion that creates safety hazards and aesthetic problems.
Solution Approach 2:
The length parameter of the threaded rod is optimized for each specific application rather than using fixed standard lengths. This allows precise control over the protruding length, ensuring it is sufficient for washer and nut attachment while minimizing excess that could cause tripping hazards or aesthetic issues.
3Object-affected harmful factors
If threaded rod is cut to reduce protrusion, then safety and aesthetics improve, but additional steps and sharp edges are created
Solution Approach 1:
The threaded rod is supplied pre-cut to the required length before installation, eliminating the need for on-site cutting operations. This preliminary preparation removes protrusion-related hazards while avoiding the complexity and safety issues of现场 cutting and edge treatment.
Solution Approach 2:
The threaded rod is treated as a disposable component that is supplied in the exact length needed for each application. Rather than cutting and reusing, a new appropriately-sized threaded rod is used for each installation, eliminating cutting operations and associated hazards while maintaining simplicity.
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 approach enables the production of expansion anchors in specific lengths required by users, optimizing results, reducing inventory burdens, and enhancing environmental sustainability by maximizing raw material efficiency and minimizing waste.
Implementation Method 1
The expansion part 30 is then welded to an end of the threaded rod 20
Implementation Method 2
continued tightening of the nut 7 causes the expansion element 3 to be drawn into the expansion sleeve 4. Due to the conical shape of the expansion element 3 this causes the expansion sleeve to deform and urge with increasing force against the concrete
Data Source
Figure 1~3
Figure 4~6
Figure 7
AI summary
A method of making an expansion anchor comprising the steps of: providing a metal rod having a thread along at least part of its outer surface; adapting the metal rod to obtain a required length of metal rod; welding an expansion section to an end of the obtained length of metal rod; and providing an expansion sleeve which in use interacts with the expansion section for increasing the expansion sleeve diameter. An expansion anchor comprising a threaded rod part, an expansion section welded to an end of the rod part and an expansion sleeve which in use interacts with the expansion section for increasing the diameter of the expansion sleeve.