AU3230299A - An anchor mounting and installation method - Google Patents

Description

S F Ref: 465684

AUSTRALIA

PATENTS ACT 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT 4 4

ORIGINAL

Name and Address of Applicant: j 4 Armacel Pty Limited 321 Mona Vale Road Terrey Hills New South

AUSTRALIA

Wales 2084 S 4 #4 S* S *e 5 *4 Actual Inventor(s): Address for Service: Invention Title: ASSOCIATED PROVISIONAL [31] Application No(s) PP3788 Frank Anthony Matich Spruson Ferguson, Patent Attorneys Level 33 St Martins Tower, 31 Market Street Sydney, New South Wales, 2000, Australia An Anchor Mounting and Installation Method APPLICATION DETAILS [33] Country

AU

[32] Application Date 29 May 1998 The following statement is a full description of this invention, including the best method of performing it known to me/us:- 5815 AN ANCHOR MOUNTING AND INSTALLATION METHOD The present invention relates to anchor mountings for fasteners and, in particular, to an anchor mounting for use with inherently weak material such as expanded polystyrene (EPS).

Because of its many advantages including low cost and low weight, many products are moulded from EPS and similar expanded polymer products. Such products include helmets for bicyclists, coolers or ice chests for retaining drinks in a cold state, and so on. Hitherto, where a mounting is required, for example in order to provide a i pivot point for the helmet visor or a mounting for the handle of the cooler, then the o10 precise position and nature of the mounting must be known prior to moulding. In particular, it has hitherto been necessary for the mounting to be located in the mould *"*prior to the moulding process in order that the mounting may be adequately embedded within the moulded material. Further, such mountings are normally immoulded, that is encapsulated within the material, but not structurally bound with the material (eg. able to withstand tensile loads). Consequently such encapsulation can actually weaken the EPS or similar material.

The requirement to pre-locate such mounting devices is disadvantageous since *0it slows down the moulding procedure. In addition, where different stock items are to 0 be produced which are the same, other than for the position or type of a mTnounting, then it is necessary for the different items be moulded each with a corresponding different mounting. However, if the mounting could be satisfactorily embedded within the moulded article after it has been moulded, then a single moulded article could be used with different types of mounting. The necessary type of mounting could then be inserted in identical moulded articles in accordance with orders received. In this way the stock of moulded articles held prior to receipt of orders could be reduced.

It is the object of the present invention to substantially overcome the abovementioned disadvantages and substantially achieve the abovementioned advantage.

In accordance with a first aspect of the present invention there is disclosed an anchor mounting for inherently weak materials, said mounting comprising a hollow [N:\LBLL]02796:DMB:TCW -2shank having a large pitch external helical spine extending therealong, said shank further having an interior adapted to receive and mate with a fastener.

Preferably the shank has a cutting edge at one (leading) end thereof and an annular flange at the other end thereof.

Preferably the interior of the shank is internally threaded to mate with a conventional threaded bolt.

Preferably the interior and exterior of the shank communicate via a plurality of openings.

In accordance with a second aspect of the present invention there is disclosed a method of installing a fastener in an anchor mounting in an inherently weak material, said method comprising the steps of: inserting a leading end of a shank of said anchor mounting into said material, said shank being hollow and having a large pitch external helical spine extending therealong; (ii) rotating said anchor mounting about the longitudinal axis of said shank to thereby rotate said helical spine within said material and draw said shank into said material; and (iii) engaging said fastener in the hollow interior of said shank.

Preferably the interior and exterior of said shank communicate-via a plurality of openings and prior to step (iii) above said method comprises the further steps of: (iv) inserting a flowable hardenable glue into said shank interior, and forcing said glue through said openings to adhere the exterior of said shank to said material.

Preferably the interior of said shank is threaded and the fastener comprises a bolt whereby said forcing step comprises the step of: locating a wad at the tip of said bolt and threadably engaging said bolt with the interior of said shank.

It is thought that the screwing in action increases the EPS density in the vicinity of the mounting which can result in increased strength. Further, the glue can saturate [N:\LIBLL]02796:DMB:TCW this region of higher density since it is permeable, to both bond the mounting to the EPS and also further increase the EPS strength.

Two embodiments of the present invention will now be described with reference to the drawings in which: Fig. 1 is a perspective view of the anchor mounting of a first embodiment, Figs. 2-5 illustrate in cross-section sequential steps in a preferred method of installing the anchor mounting of Fig. 1, Fig. 6 is a view similar to Fig. 5 but illustrating an alternative fastener, 7 and 8 illustrate in cross-section sequential steps in the installation of an 10 alternative anchor mounting, and Figs. 9-15 repeat Figs. 2-8 save that the anchor is located under the skin(s) prior to its (their) formation.

As seen in Fig. 1, the first form of the anchor mounting 1 of the present invention has a hollow cylindrical shank 2 with a cutting edge 3 at one (leading) end or tip 4 and an annular flange 5 at its other end. The shank 2 has a hollow interior 6 which is threaded at 7. A plurality of small holes 8 connect the interior and exterior of the shank 2.

*"The exterior of the shank 2 is provided with a large pitch external helical spine 9 which forms an external screw. The spacing between the turns of the spine 9 is of the same order of magnitude as the diameter of the shank 2 and the height of the spine 9 is preferably approximately half the diameter of the shank 2 and can be up to approximately one shank diameter, if desired.

Turning now to Fig. 2, illustrated therein in cross-sectional fashion is a moulded article 11 which preferably is provided with an exterior skin 12 utilising the ARMACEL (Trade Mark) process described in detail in International Patent Application No. PCT/AU95/00100 published under No. WO 95/23682 the contents of which are hereby incorporated by cross-reference as a convenient means of describing the possible range of moulded articles 11.

[N:\LIBLL]02796:DMB:TCW As indicated in Fig. 2, the anchor mounting 1 is inserted in the desired position in the moulded article 11 by forcing the tip 4 through the skin 12 and rotating the mounting 1 in a clockwise direction as indicated by the arrow in Fig. 2 in order to turn the shank 2 about its longitudinal axis. As a consequence, the shank 2 is drawn into the body of the moulded article 11 in the manner of a self tapping screw. This action displaces moulded material having a volume approximately equal to the volume of the shank. This thereby increases the density and strength of the moulded material in the region adjacent to the inserted shank. This is indicated by a number of closely spaced .dots in the drawings. Since the material 13 from which the moulded article 11 is 10 formed is inherently weak, the anchor mounting 1 can be rotatably inserted into the a. a moulded article 11 by hand without the need for any special tools. If desired, a bolt or *°°°:other threaded device having an external thread of the same diameter but different pitch 0from thread 7, can be inserted into the hollow interior 6. Under these conditions, the threads partially engage and this provides a convenient driving tool for the anchor mounting 1. Since the threads are of different pitches, they will only engage over a 0short length but this is sufficient to rotate the anchor mounting 1. If such a device is 00.0 used, as soon as the anchor mounting 1 is fully inserted as indicated in Fig. 2, the temporary driving tool can be rotated in a reverse direction and the threads can thereby 0 o be disengaged.

In some instances, particularly where the anchor mounting 1 is in compression (such as providing a mounting for a threaded foot in the base of an article), the above described process completes the installation of the mounting, and the threaded foot (not illustrated) can be simply engaged with the thread 7 of the hollow interior 6.

However, in most instances it is necessary to resist substantial tensional and/or shear forces applied to the anchor mounting 1. Under these circumstances the preferred course of action is as illustrated in Figs. 3-4. Here a glue 15 is inserted into the hollow interior 6 with a view to being forced out of the holes 8 so as to bring the glue 15 into contact with the inherently weak material 13. If desired this can be accomplished by applying compressed air to the hollow interior 6 thereby driving the glue 15 through the [N:\LIBLL]02796:DMB:TCW holes 8. The preferred glue is that manufactured by 3M of the U.S.A. and sold under the trade names JET WELD (for a hot glue) or SCOTCH 34R (an insulation adhesive for a cold glue).

However, an alternative, and preferred, method is illustrated in Fig. 4 where a small piece of wadding 16 is positioned in the hollow interior 6 and a conventional bolt 17 with a lock nut 19 is engaged with the thread 7. By rotation in the clockwise direction as indicated in Fig. 5 the wadding 16 is driven into the hollow interior 6 of the shank 2. As a consequence, the glue 15 is forced through the holes 8 and adheres the exterior of the anchor mounting 1 to the material 13. The lock nut 17 is tightened to hold the bolt 17 in position. The glue 15 also permeates the adjacent area. As the glue sets this substantially increases the area of support.

As indicated by Fig. 6, the bolt 17 of Figs. 4 and 5 can then, if desired, be S°withdrawn (the lock nut 17 being released) and be replaced by a specialised fastener .such as an eye-bolt 18.

It will be apparent that the anchor mounting 1 is conveniently provided with a cutting edge 3 at its tip 4 and, as illustrated in Figs. 4 and 5, this provides a relatively large space within the material 13 which is filled with the glue 15. However, it is not °necessary that such a cutting edge be provided.

o *As illustrated in Fig. 7, a second form of anchor mounting 21 is illustrated which has a square tip 24. This device is particularly for use with those articles 31 having a pair of opposed skins 32. Under these circumstances the length of the shank 22 of the mounting 21 is selected to be substantially equal to the spacing between the two skins 32.

In the arrangement illustrated in Fig. 7, the anchor mounting 21 is inserted as before and a bolt 27 is passed through the hollow interior 6 and engaged with a conventional washer 29 and nut 30 as illustrated in Fig. 8 so as to place the inherently weak material 13 in compression.

In Figs. 7 and 8 either the interior 26 of the mounting 21 is smooth and of bore slightly larger than the diameter of the shank of the bolt 27, or conversely the interior [N:\LIBLL]02796:DMB:TCW

M

26 is threaded and therefore threadably engages the bolt 27. In both Figs. 7 and 8 no glue is used and thus the holes 8 remain empty.

Figs. 9-15 essentially repeat the same information as in Figs. 2-8 respectively, save that the anchor mounting 1, 21 is inserted into the inherently weak material before the skin(s) 12, 32 are applied. A small portion of skin 12, 32 is then cut away to reveal or expose the hollow interior 6. The remaining procedures are as previously described.

The foregoing describes only some embodiments of the present invention and modifications, obvious to those skilled in the art, can be made thereto without departing from the scope of the present invention. For example, the holes 8 can vary in diameter 10 along the length of the shank 2, in order to control the amount of adhesive deposited :between the material 13 and the shank 2 in different positions along the length of the 9shank. Also, instead of using a wad and bolt as a "glue chaser", one end of the anchor in Figs. 7, 8, 14 and 15 can be blocked off and compressed air used instead to force the glue into the material 13. Similarly, the flange 5 can include a series of holes through which the skin 12 of Figs. 9-15 penetrates to provide additional locking.

S .i 9 a *o.

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Claims (10)

1. An anchor mounting for inherently weak materials, said mounting comprising a hollow shank having a large pitch external helical spine extending therealong, said shank further having an interior adapted to receive and mate with a fastener.

2. The anchor mount of claim 1 wherein the shank has a cutting edge at one (leading) end thereof and an annular flange at the other end thereof.

3. The anchor mounting of either of claims 1 and 2 wherein the interior of the shank is internally threaded to mate with a conventional threaded bolt. go 10

4. The anchoring mounting of any one of claims 1 to 3 wherein the o* S" interior and exterior of the shank communicate via a plurality of openings.

5. A method of installing a fastener in an anchor mounting in an inherently weak material, said method comprising the steps of: inserting a leading end of a shank of said anchor mounting into said material, said shank being hollow and having a large pitch external helical spine :extending therealong; (ii) rotating said anchor mounting about the longitudinal axis of said shank "to thereby rotate said helical spine within said material and draw said shank into said S"material; and (iii) engaging said fastener in the hollow interior of said shank.

6. The method of claim 5 wherein the interior and exterior of said shank communicate via a plurality of openings and prior to step (iii) said method comprises the further steps of: (iv) inserting a flowable hardenable glue into said shank interior, and forcing said glue through said openings to adhere the exterior of said shank to said material.

7. The method of claim 6 wherein the interior of said shank is threaded and the fastener comprises a bolt whereby said forcing step comprises the step of: [N:\LIBLL]02796: DMB:TCW locating a wad at the tip of said bolt and threadably engaging said bolt with the interior of said shank.

8. An anchor mounting for inherently weak materials, substantially as hereinbefore described with reference to Figures 1 to 6 or Figures 7 and 8 of the accompanying drawings.

9. A method of installing a fastener in an anchor mounting in an inherently weak material, said method being substantially as hereinbefore described with reference to Figures 1 to 5, Figures 1 to 6, Figures 7 and 8, Figures 9 to 12, .Figures 9 to 13 or Figures 14 and 15 of the accompanying drawings. C

10 Dated 28 May, 1999 Armacel Pty Limited t Patent Attorneys for the Applicant/Nominated Person SPRUSON FERGUSON o. [N:\LIBLL]02796:DMB:TCW