The present invention relates to the field of anchors used to fasten an object to a surface of a panel.
Anchors are attached to panels by different designs and methods. Typically, anchors are consisted of a fastening receiver such as a nut attached to an anchor body. A fastening rod such as a screw or a bolt is fastened into the fastening receiver and forces applied on the fastening receiver are transmitted and distributed by the anchor body to a contact area of the panel. Counter forces generated by the panel counteract the forces transmitted to the panel. Most anchors are inserted through an insertion hole made in the panel. Some anchors are attached to the hole itself as they expend inside while other anchors use the back surface of the panel to counteract forces apply on them.
Expending anchors are most useful in solid materials like wood, concrete, brick, mortar or metals. Expending anchors expand when fastening rods are inserted or threaded into the fastening receivers and produce high shear forces that prevent the anchors from dislodging. Therefore, the strength of the expending anchors depends on the strength of the material of the panel.
Back-surface anchors are designed to be used in thin panels or in hollow walls. Back-surface anchors are inserted through an insertion hole in a panel and they are designed to open-up or spread behind the panel in a way that they cannot be pulled back through the insertion hole. The strength of a Back-surface anchors is proportional to the size of the back-surface contact area and more specifically, the length of the circumference of that area. Back-surface anchors could theoretically provide amazing resistances despite a relatively weak material of the panel.
It is extremely important to match the right anchor with the material of the panel, the expected forces applied on the anchor and the direction of the forces. An anchor that is mismatched with the expected load, usage and the material of the panel will eventually loosen up and damage the panel.
The most commonly used expanding anchors are the push-in plastic expansion anchors (for example, U.S. Pat. No. 1,878,600). They are available in many sizes and designs. When a screw is threaded into a plastic anchor it expands, exerting forces against the walls of the hole. Better expansion anchors are made of lead and metal. The stronger the panel material, the stronger the resistance provided by the expansion anchor. Push-in plastic expansion anchors may provide pulling resistance of around 30 pounds in concrete but less than 10 lbs in drywall. Generally speaking, plastic anchors hold well vertical forces such as hanging a picture frame but may be too weak for pulling forces that are perpendicular to the panel plan.
Threaded drywall Anchors (for example, U.S. Pat. 8,192,123 B2), represent an improvement over the push-in plastic expansion anchors. Those anchors are threaded into the dry wall by a Philip's head fastening driver. Threaded drywall anchors are available in both nylon and metal and provide a better pulling resistance of about 15 lbs to 25 lbs in dry wall. Although threaded Drywall Anchors are stronger than push-in plastic anchors, they still should be used primarily for vertical forces and should not be used for significant pulling forces.
A commonly used back-surface anchors are the winged plastic Anchors (for example, U.S. Pat. No. 4,993,901). This winged plastic anchors double the pulling resistance of a push-in plastic expansion anchors to about support from 25 to 35 lbs in drywall. As a fastening rod is inserted into a winged plastic anchors, the wings of the anchor are pushed out against the back of the panel. Tightening the fastening rods too much may cause damage to the threads resulting in a weaker anchor.
Sleeve-type anchors have a better opening or spreading mechanism as they are combine a screw, a sleeve and a compression mechanism (for example, U.S. Pat. No. 2,918,841, U.S. Pat. No. 3,143,915 and U.S. Pat. No. 4,720,224). The sleeve-type anchors are easily pushed into a hole and as the fastening rod tightens the sleeve folds outwards and creates ‘teeth’ that hold the anchor against the backside of the panel. In hollow dry walls, sleeve-type Anchors can hold up to 50 lbs. In solid materials like a concrete wall, the sleeve-type anchors are actually very useful and provide good resistance to pull forces.
The toggled anchors are back-surface anchors. The toggled anchors may either use hinged wings or a bar that distribute forces applied on the fastening receiver. Hinged wings type toggled anchor (for example, U.S. Pat. No. 3,389,631) looks like a pair of spring-loaded metal wings attached to a central fastening receiver having a long fastening rod. When the toggled anchor is inserted through the hole, the wings are folded toward the central fastening rod. Once the wings pass the thickness of the panel, they open up and press against the back surface of the panel as the fastening rod tightens. The strength of a traditional Wings type toggled anchor is about 30 lbs for a ⅛″ toggled anchor and 50 lbs for a ⅜″ toggled anchor. Bar type toggled anchors (for example, U.S. Pat. No. 549,069, U.S. Pat. No. 1,003,527, U.S. Pat. No. 1,061,480, U.S. Pat. No. 1,159,420 and many more) provide a larger contact area with the back surface of the panel. The size of the contact area is very important in preventing damages to the material of the panel.
A SnapToggle anchors have several advantages over other types of bar type toggle anchors. (For example, US Patent Application 2011\0268528). The SnapToggle anchor is easy to insert and maneuver and it contains a plastic cap that slides over two plastic straps and locks the anchor in the insertion hole. The SnapToggle anchor is using a U shape bars that provide pull force up to 265 lbs in ½″ drywall. The advantage of a U shape bars is the long contacts circumference lines with the back surface of the panel and hence a better pulling resistance, however the disadvantage of a U shape bar is the very small contact area, which increases the risk of damages to the dry wall and overtime it may resulted in loosening of the anchor. A similar idea to the SnapToggle anchor is shown in another US patent (US Patent Application 2014\0102040). The anchor is actually based on a flat metal bar inserted through the insertion hole into to the space behind the panel. The metal bar is pulled by a cord that substitutes the role of the cap and the straps.
There are certainly many more patents, patents applications and different designs that represent combinations, variations, modifications, improvements, enhancements and different uses of the basic anchors discussed above. Some of them provide real additional advantages while other may have no added value or may even be inferior to the anchors presented above. In summary, a good anchor design must be simple, ‘fool proof’, inserted through a small hole as possible, have a larger contact area on the back surface of the panel and have a smaller risk of future loosening of the anchor and/or damages to the panel. Therefore, despite numerous solutions and designs of anchors, there is still a need for better and simpler anchor, which is the objective of the current invention.
The available anchors are products of our symmetrical thinking. The insertion hole creates an imaginary axis perpendicularly to the plane of the panel. Because of our symmetrical thinking, we rotate parts of the anchor away from the imaginary axis to hold the anchor in place. However, a non-symmetrical approach opens a door to a host of new anchors designs and creates numerous possibilities and combinations of anchors that offer significant improvements over the current art
The folding non-symmetrical anchor is built from at least two consecutive members inserted through an insertion hole of the panel from the first member to the last member. Each two consecutive members are coupled by means for repositioning one member relatively to the other. Initially, those two consecutive members are positioned away from each other for the insertion through the insertion hole, but as the leading member of the two consecutive members passes the thickness of the panel and enters the space behind the panel, it repositions towards its trailing member. This process folds the anchor behind the panel. The last member is mounted into the insertion hole and thereby it controls the final position of each member of the anchor behind the panel. A member that is not the last member comprises a fastening receiver such as a nut. A fastening rod such as a screw or a bolt is inserted through the insertion hole is fastened into the fastening receiver. A stack of contiguous members having at least the one member comprises the fastening receiver is contiguous to a portion of the back surface of the panel and transmit and distribute pulling forces applied by the fastening rod on the fastening receiver to the panel. The panel generates counter forces that counteract those pulling forces. A common means for repositioning is a pivoting axis. A pivoting axis couples two consecutive members rotates the leading member relatively to its trailing member. A spring can be used to rotate members to theirs final position but gravity can be used as well. The pivotal axis between two members does not have to be positioned at the very end of the members. The pivotal axis could be positioned at other points along the members as long as the leading member can rotate in the space behind the panel and fulfill its function.
Another means for repositioning is an elastic connector coupling two consecutive members. This type of means for repositioning is especially useful for inexpensive anchors made of materials such as plastic and nylon. Elastic connectors could be used for two-dimensional movements but elastic connectors could be used for complex three-dimension movements. Other means for repositioning include but not limited to combinations of several pivoting axes, sliding mechanisms, ball and socket joint mechanisms and combination of means.
In a simple embodiment, the anchor is built of two members coupled by a pivotal axis. The anchor is inserted in its unfolded form. Once the first member passes the thickness of the panel and reaches the space behind the panel, it rotates against the second member, which is the last member of the anchor. The last member of the anchor comprises means for mounting including a ring that mounts into the insertion hole and a disk that lays against the frontal periphery of the insertion hole, thereby, the second member is controlling the position of the first member behind the panel.
In other embodiments, the anchor is built of three members or more. Each two consecutive members are coupled by means for repositioning such as a pivotal axis. The anchor is inserted in its unfolded form. Once the first member passes the thickness of the panel and reach the space behind the panel, it rotates against the second member of the anchor. Then as the second member passes the thickness of the panel, it also rotates against the third member and so forth. The last member of the anchor has means for mounting in the insertion hole. This last step controls the final position of the members behind the panel.
In yet other embodiments, at least one member of the folding anchors further comprises an additional at least one sub-member and means for repositioning such as a pivotal axis. In one of the embodiments, once the sub-member passes the thickness of the panel and reaches the space behind the panel, the sub-member turns in about 90 degrees to the originating member and creates a cross-like structure that further increases the contact area between the folding anchor and the back surface of the panel.
In additional embodiments, at least one member of the folding anchor further comprises an additional at least one sub-member that is branching away from the member by means for repositioning such as a pivotal axis to further increase the contact area with the back surface of the panel.
In some embodiments, the members do not reposition against each other but rather a side-by-side. Those embodiments allow leading members to reach the back surface of the panel. In one example of those embodiments, the anchor is made of two members. The first member is a metal bar having a pivoting axis on one end and a about centrally located fastening receiver. The second member is coupled at one end to the pivoting axis by a side-by-side configuration to the first member and on the other end of the second member comprises means for mounting including a ring and a disk that mount into the insertion hole. As the metal bar passes the thickness of the panel and reaches the space behind the panel, it rotates until it lay against the back surface of the panel. The fastening receiver of this metal bar is aligned with the insertion hole.
In an economical version of the last embodiments, a simpler and cheaper elastic connector is substituted as means for repositioning. A variety of materials can be used including metal, plastic and/or nylon. The anchor comes in its folded final position. The members of the folded anchor are unfolded and inserted consecutively in a zigzag fashion into the insertion hole and the last member is mounted into the insertion hole.
Yet other embodiments further include means for triggering. Members of the anchor are locked in their unfolded position by the means for triggering. Releasing the locked members to their final positions by the means for triggering is decided and timed by the operators. A pull rod or a sleeve that could be pulled back as the anchor is inserted provides an illustration of this concept. The exposed members of the anchor will then fold to their final position. Embodiments may further combine means for preventing rotation of the fastening receiver and/or any other member that is subjected to shear forces generated by the threading of the fastening rod into the fastening receiver. Means for preventing rotation may further wedge into the back surface of the panel and prevent damage and distortion of the folding anchor. Embodiments may further include means for preventing non-flushed seating of the stack on the back surface of the panel. During drilling of an insertion hole in the panel, some material of the panel can be pushed backwards creating a hump of the back surface of the panel around the insertion hole. This may happen when drilling is done too fast or forcefully. Mon-flushed seating of the stack on the back surface of the panel will result in fastening receiver that is not perfectly perpendicular to the panel resulting in difficulties of fastening the fastening rod into the fastening receiver. Means for preventing non-flush seating provide some space for pushed back panel material around the rim of the insertion hole that does get in the way between the frontal surface of the stack and the back surface of the panel.
The current disclosure is also a novel method of inserting an anchor into a panel. The first step of the method is creating an insertion hole in said panel in a predetermined size and location for the insertion of the folding anchor. The next step is insertion of the members of the folding anchor consecutively from a first member to a last member. Each subsequent member of the folding anchor pushes each leading member into a space behind the panel where the leading members fold into their final position. The next step is mounting the last member into the insertion hole and essentially establishing the final position of all the members of the folding anchor. The next step is insertion of a fastening rod that is fastened into a fastening receiver of the folding anchor. The fastening rod transmits pulling forces to said fastening receiver and from there, the pulling forces are transmitted and distributed via a stuck of at least one member a portion of the back surface of the panel. The panel generates counter forces that counteract the pulling forces
The different embodiments and methods disclosed in this application are just some examples to the host of implementations and combinations possible with the novel concept of the folding anchor. Some features, options, and advantages may be shown in certain embodiments but may not be shown in other. And yet, any part of the subject matter of the present invention may be combined in any suitable manner in one or more embodiments, designs and/or implementations. Any part of the present disclosure may be also incorporated into existing anchors. Furthermore, designs, structures, materials, features or operations may not shown or described in detail to avoid obscuring aspects of the subject matter of the present disclosure. The current disclosure describes the principals, concepts, details, designs, features, methods, structures, characteristics and/or advantages of the novel anchor so that anyone skilled in the art can understand and implement either all or any part of the subject matter. The features and advantages of the subject matter of the present disclosure will become more fully apparent from the following description and appended claims, or may be learned by the practice of the subject matter as set forth hereinafter.
101—Second member
102—Fastening receiver
103—First pivotal axis
104—First Member
105—Second pivotal axis
106—Third Member
107—Insertion hole mounting ring of forth Member
108—Insertion hole mounting disk of forth Member
109—Conduit
110—Rotational arrow showing the direction of the first member
111—Rotational arrow showing the direction of the second member
112—Means for triggering release of members to reposition in a form of a Pull-Rod
113—Arrow showing the direction of the Pull-Rod
114—Third pivotal axis
115—Arrow showing the direction of the third member
151—First member having different thicknesses and a fastening receiver
152—Pivotal axis
153—Second Member
154—Insertion hole mounting ring
155—Insertion hole mounting disk
156—Fastening receiver
157—Rotational arrow showing the direction of the first member
201—Second member having a fastening receiver
202—Fastening receiver
204—Sub-Member means for repositioning and means for passage of a fastening rod
205—Sub-member
206—First pivotal axis
207—First Member
208—Second pivotal axis
209—Insertion hole mounting ring
210—Insertion hole mounting disk
211—Conduit
212—Rotational arrow showing the direction of the first member
213—Rotational arrow showing the direction of the second member
215—Third member
217—Sub-member
218—Sub-member
219—Rotational arrow showing the direction of sub-member 217
220—Rotational arrow showing the direction of sub-member 218
221—Means for repositioning sub-member 217
222—Means for repositioning sub-member 218
301—First member
302—Pivotal axis
303—Second Member
303—Insertion hole mounting ring
305—Insertion hole mounting disk
306—Rotational arrow showing the direction of member 301
307—Conduit
308—Fastening receiver
401—First member
402—Second member made of two bended wires having some elastic properties
403—Pivotal axis
404—Rotational spring
405—Insertion hole mounting ring
406—Insertion hole mounting disk
407—Fastening receiver
408—Rotational arrow showing the direction of the first member 401
408—Panel
501—Second member
502—Fastening receiver in the form of a nut
503—Pivotal axis
504—Third member
505—Insertion hole mounting ring
506—Insertion hole mounting disk
507—Conduit
508—Pivotal axis
509—first member
510—A passage for the fastening rod
511—Rotational arrow showing the direction of the second member 501
512—Rotational arrow showing the direction of the first member 509
601—Second member
602—A passage for the fastening rod in the Second member 601
603—means for preventing rotation by shear forces created by threading of the fastening rod
605—Elastic connector
606—Elastic connector
608—A fastening receiver of the first member
609—Insertion hole mounting ring of the third member
610—Insertion hole mounting disk of the third member
701—Second member
702—A passage for the fastening rod in the Second member 701
703—Elastic connector
704—First member
705—Fastening receiver
706—Elastic connector
707—Insertion hole mounting ring of the third member
708—Insertion hole mounting disk of the third member
709—A Conduit
801—First member
802—Second member
803—Insertion hole mounting ring of the Second member
804—Insertion hole mounting disk of the Second member
805—Elastic connector
806—Fastening receiver
807—A Conduit
808—Means for preventing non-flushed seating of the stack on the back surface of the panel in the form of a space created around the mounting ring.
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