MODULAR ADHESIVE ANCHOR SCREEN

A modular adhesive insert for a construction anchor allows for controlled dispersion of adhesive in a pre-formed bore, and multiple insert screens to be attached to each other to create many sizes of screens. The insert comprises an end cap and also includes an abutment structure. The insert includes a housing with a first end and a second end, the first end including a first set of connection structures, the second end including a second set of connection structures, the housing including a plurality of shutters between the first end and the second end, each of the shutters adapted to vary a size of an opening associated with each said shutter.

BACKGROUND

Apertured sleeves are used in various cases when setting an adhesive construction anchor in the face of a wall or other foundation material. An adhesive anchor should be completely surrounded by the adhesive or mortar, and the adhesive should completely fill the space between the anchor and the wall of the bore. Currently, screen tubes or plastic screens retain the adhesive and prevent it from falling into the hollow cavity in the base material during installation. The adhesive flows out of the screen or tube when the anchor is inserted into the screen, and bonds with the solid parts of the base material.

Apertured sleeves are also useful when the anchor is set in a hollow substrate or a substrate with an internal open space or spaces such as bricks, concrete blocks, or concrete masonry units (CMU). The screen-type insert serves to keep the adhesive close to the anchor. Setting an anchor in a substrate having interior voids creates further difficulties for the insertion of adhesives. Not only can the adhesive flow too far into the bore away from the anchor, and drip down from the upper surfaces of the bore, but it can literally fall into the void completely away from the anchor.

Concrete blocks are generally cement and/or concrete formed into rectangular cells. Concrete blocks and concrete masonry units are hollow rather than solid rectangular blocks. A typical concrete block or CMU is generally a rectangular block with4full sides or shells surrounding a cavity that opens outwardly through the top and bottom surfaces. Wider concrete blocks and concrete masonry units may be formed with a web that divides the cavity and spans the distance from one side of the block to the other. The walls of the concrete block or CMU can be narrow or thicken depending on the strength needed for the block.

One issue that arises with the use of apertured sleeves is that different sizes of apertures need to be provided for different types of adhesives. Because of multiple components and assembly process, current plastic screens have become very expensive. Limited suppliers of the mesh tubes also raised potential supply chain disruptions, and the screens are only available in limited lengths due to the low volumes and need to make a new mold for each length. Builders thus may have to purchase apertured sleeves or screens that are not optimized for the length of their application because of a limited length selection. In addition, a different aperture size is generally needed for each different adhesive due to differences in adhesive chemistry, including different particle sizes and viscosities.

SUMMARY

The technology relates to an improved connection between an anchor or fastening element in a substrate, such as masonry, cement, or stone, using an adhesive or mortar compound to make the connection, and more particularly, provides an improved apertured or porous sleeve-shaped member for use with the anchor and the adhesive.

One general aspect includes a modular adhesive insert for a construction anchor. The insert comprises a first plastic insert comprising housing with a first end and a second end, the first end including a first set of connection structures. The second end includes a second set of connection structures. The first set of connection structures are adapted to connect to the second set of connection structures of a second plastic sleeve, and the body includes a plurality of shutters between the first end and the second end.

Implementations may include the insert where the plastic insert includes a plurality of apertures coincident with the shutters. Implementations may include the insert further including a first end cap and a second end cap, the first set of connection structures adapted to connect to the first end cap and the second set of connection structures adapted to connect the second end cap to the plastic sleeve. Implementations may include the insert where each shutter has at least an open side, a second side opposing the open side and two sides defined by an indentation in the housing and positioned between the open side and second side.

Implementations may include the insert where each shutter has at least a hinged side, a free end opposing the hinged side, and two free sides between the hinged side and the free end. Implementations may include the insert where each of the plurality of shutters includes the hinged side perpendicular to a central axis of the screen such that each shutter opens along an axial length of the screen. Implementations may include the insert where each of the plurality of shutters includes the hinged side parallel to a central axis of the screen such that each shutter opens along a radial length of the screen. Implementations may include the insert where each of the plurality of shutters includes an interior side and an exterior side, and a cam on the interior side of the shutter. Implementations may include the insert where each of the plurality of shutters includes and interior side and an exterior side, and a cam on the exterior side of the shutter. Implementations may include the insert wherein the screen includes a plurality of panels interleaved with the plurality of shutters, and wherein ones of the panels and ones of the shutters include apertures. Implementations may include the insert where the first set of connection structures may include posts. Implementations may include the insert where the second set of connection structures may include notches.

Another aspect includes A modular adhesive screen for an anchor insert assembly for use in a bore in a substrate. The screen includes a body having a first end and a second end, and a length between the first end and the second end. The body has a tubular shape defined by one or more outer surfaces, the one or more outer surfaces including a plurality of shutters, each of the shutters configured to vary an opening associated with the shutter upon installation of the insert assembly.

Implementations may include the screen where the shutters vary in size as the screen is inserted into the bore. Implementations may include the screen where each of the plurality of shutters includes and interior side and an exterior side, and a cam on the exterior side of the shutter. Implementations may include the screen wherein the anchor insert assembly includes an anchor rod inserted into the screen, and the shutters vary in size as the anchor rod is inserted into the screen. Implementations may include the screen each of the plurality of shutters includes an interior side and an exterior side, and a cam on the interior side of the shutter. Each of the plurality of shutters has at least a hinged side, a free end opposing the hinged side, and two free sides between the hinged side and the free end. Implementations may include the screen each of the plurality of shutters includes the hinged side perpendicular to a central axis of the screen such that each shutter opens along an axial length of the screen. The screen includes a plurality of panels interleaved with the plurality of shutters, and where ones of the panels and ones of the shutters include apertures.

DETAILED DESCRIPTION

The present technology roughly described provides an improved insert for use in adhesively securing construction anchors in a substrate. The insert is a modular adhesive insert for a construction anchor that allows multiple insert screens to be attached to each other to create various sizes of screens, and which is created by a relatively simple injection molding process to provide different variations of insert which can be used with multiple types of adhesives. The insert comprises an end cap and also includes an abutment structure (or second end cap). The insert includes a plastic insert having a first end and a second end, the first end including a first set of connection structures such as posts, and the second end including a second set of connection structures such as notches. The first set of connection structures is adapted to connect the end cap to the plastic sleeve, and the second set of connection structures is adapted to connect the abutment structure portion to the plastic sleeve. The first set of connection structures is further adapted to connect the first end of the plastic insert to the second set of connection structures on a second plastic sleeve.

FIGS.1and2A-2Eshow an apparatus and a method of forming a connection, between a substrate1and an anchor2by means of adhesive3.FIGS.1and2A-2Eare reproduced from U.S. Pat. No. 7,837,018.

A substrate1is first formed with a bore4therein. To facilitate the connection between the anchor2and the substrate1a porous screen5is used. Screen5is received by bore4in substrate1. Screen5is formed from a frame7and a tube7. A distal end12of frame7is inserted first into the bore and a trailing or anchor receiving end15is visible when the screen5is inserted into the bore4. The leading axial section13of the frame7is formed with apertures14and tube7has apertures17formed therein.

The tube7is received by frame7, such that at least a portion of the tube7overlaps a portion of the leading axial section13. Because there are apertures14in the leading axial section13and apertures17in the tube7, a fluid material disposed within the interior area8enclosed by frame7and at the leading axial section13could be forced radially outwardly through the apertures17in the tube7, and through the apertures14in the leading axial section13of the frame7to reach the exterior9of the frame7.

As shown inFIGS.2A and2B, an injection gun is typically used for filling an adhesive into the tube7and the screen5can be filled with a cap39having an opening for receiving the nozzle41of an injection gun in place if desired. The adhesive3is disposed within the interior area8of the frame7and the adhesive3is forced out of the frame7through the apertures17in the tube7and the apertures14in the axial section13of the frame7.

As shown inFIGS.2C and2D, when the substrate comprises a concrete masonry unit or other hollow substrate30, and the user desires to set the anchor in both a first web31and a second web33of the substrate30, the screen5needs to be stiff enough, when filled with adhesive3, to be inserted into a first bore4formed in a first web31of a hollow substrate30, extend across an interior cavity32of the hollow substrate30, and be received in second aperture formed in the second, opposite web33of the hollow substrate30.

As shown inFIGS.2C-2E, the screen has an outer diameter35selected to cooperate with the diameter of the bore4or aperture in the substrate1or the first and second bores4and34in the first web31and second web33of a hollow substrate30. When a fastener or anchor2is inserted into the cylindrical screen5, the adhesive3is disposed within the screen5will be prevented from being axially discharged from the distal end12of the screen5, and will be discharged radially through the apertures14,17and19in the screen5as illustrated inFIGS.2D and2E.

As shown inFIG.2D, frame7is formed with an abutment structure37at its anchor receiving end15which determines the depth to which the screen5can be driven or inserted into the bore4. This abutment structure37may be formed by providing an annular flange at the anchor receiving end15, or as is shown inFIG.1, in the embodiment, a pair of oppositely disposed flanges38at the anchor receiving end15of the frame7.

With respect to the adhesive3, the apertures17in the mesh tube7and the apertures19in the second axial section18are designed to be used with a specific adhesive3. The characteristics of the adhesive3determine the size of the apertures17of the mesh tube7and the size of the apertures19in the second axial section18of the frame7.

For a hollow substrate, such a substrate30, the substrate is prepared by forming aligned bores4and34in the first web31and second web33of the hollow substrate30. Using a drill, a first bore4is formed in the first web31of the substrate30. The drill is then inserted further, extending across the interior cavity32of the hollow substrate30, and a second bore34is blind drilled in a second, opposite web33of the hollow substrate30.

The solution shown inFIGS.1-2Erequires multiple components and assembly, and have thus become very expensive over the years, which is the opposite of how they were intended. In addition, a different screen mesh is needed for each different adhesive due to differences in adhesive chemistry. Embodiments of the modular adhesive anchor disclosed herein address these and other issues.

FIGS.3A-3Dshow a first embodiment of a modular adhesive anchor screen300in accordance with the present technology. As illustrated inFIG.3B, an adhesive anchor screen300comprises a portion of an insert350which includes the screen300, end cap330and abutment structure340. The screen300includes a first set of connection structures comprising notches310which mate with posts311on abutment structure340to secure the abutment structure340within the interior of screen300. Screen300includes a second set of connection structures comprising posts320which mate with notches325on end cap330to secure end cap330on collar322of screen300. The notched310can be used to connect with posts320to connect multiple screens300in series to form varied sizes of inserts.

The adhesive anchor screen300is a modular, injection molded plastic adhesive screen designed to work with multiple types of adhesives. The screen300includes a variable sized mesh of apertures312,314. (InFIG.3, not every aperture or row of apertures is labeled in order to not obscure the illustration of the screen.) In one embodiment, the apertures are circular and have varying dimensions. For example, a row314aof apertures314may have a diameter of 0.015 inch and a row312aof apertures312may have a diameter of 0.010 inch. In one embodiment, the diameters of each row312a,314bof apertures alternates diameters relative to an adjacent row, and repeats over the surface of the screen. In alternative embodiments, different sized apertures are located in the same row in any number of different patterns (i.e., each row need not all be the same sized aperture.) In alternative embodiments, more than two different diameter apertures are used. Each aperture may have a different cross-sectional opening shape. For example, the apertures may be round, rectangular, triangular, oblong, star-shaped, or other geometric shapes. Further, the spacing and pattern of apertures may vary.

As illustrated inFIG.3C, screen300has a generally circular cross-section. The interior of screen300includes supporting ribs352between a leading or first end302which inserted first into a bore and a second, trailing or anchor receiving end304. In one embodiment, eight supporting ribs are provided on the interior of screen300. More or fewer ribs may be used.

To make the connection using an anchor, an adhesive3is disposed within the interior area of the screen300with the with abutment structure340and end cap330attached after the insert350is provided in a substrate. Insertion of an anchor2into the insert350(screen300with abutment structure340(or second end cap) and first end cap330attached) before the adhesive has set will force the adhesive out of the screen300through the apertures312,314. Sufficient adhesive is provided into the insert so that the adhesive completely surrounds and is in complete contact with the portion of the anchor2inserted into the screen300. Adhesive is extruded out of the screen300and into contact with a bore in the substrate1and the anchor2, through contact with the adhesive, becomes bonded to the substrate when the adhesive sets.

The varying opening size, aperture spacing, and aperture mesh pattern allows the screen300to be used with adhesives with different viscosities and/or particle size to work in the same screen. Further variations are possible by vary shape of apertures (round, rectangular, triangular, oblong, star, etc.) and with spacing/pattern.

FIGS.4A-4Eshow a second embodiment of a screen400for use in a modular adhesive insert. Screen400includes a plurality of internally activated axial shutters414which allow extrusion of adhesive as an anchor forces the shutters open during installation. (The shutters are referred to as “axial” in that they actuate outwardly along the axis (A) of the anchor inserted into the screen400.) It should be understood that screen400may also be fitted with an end cap330at a first end402and abutment structure340at a second end404in a manner similar to that shown with respect to screen300inFIG.3B. First end402includes a first set of connection structures comprising posts410to allow attachment of the end cap and a second set of a first set of connection structures comprising notches420in second end404which allows connection of an abutment structure and/or allows multiple screens400to be connected to each other, thereby allowing multiple sizes of screens to be used to create different sized inserts.

As illustrated inFIGS.4C-4E, each individual shutter414includes an angled cam or cam416, with the cam416including a lower end416acloser to the second, trailing end404of screen400, and a higher end416bcloser to the leading, first end. As best illustrated inFIG.4E, each shutter has a free end415and a hinged edge413connected to a main body for 14. The angled cam416forces the shutter414open when an anchor is inserted into the interior of screen400.

As illustrated inFIGS.4A and4C, screen400has a generally hexagonal cross-section defined by six sides405, each including axial shutters414. More or fewer sides may be used in various embodiments. The sides of shutters are separated by supporting ribs450between a leading or first end402which inserted first into a bore and a second, trailing, anchor receiving end404. In one embodiment, six supporting ribs are provided but more or fewer ribs, and more or fewer sides having axial shutters, may be used. In other embodiments, some sides need not include shutters and may be interleaved with sides containing shutters.

FIG.5illustrates an anchor2being inserted into screen400in the absence of adhesive. (Note that an adhesive would be present during installation of the anchor.) Each angled cam416engages the body of the anchor (which in the case ofFIG.5is a fastener thread). When the anchor engages a cam416of a shutter414, the shutter rotates about hinged edge413and its free end415is forced outward, allowing any adhesive in the screen to be extruded from the screen and into the substrate (or free space) in which the anchor is being installed, as shown at505. Shutters which have not been engaged remain closed and prevent extrusion of adhesive at portions of the screen where the anchor has not reached, as shown inFIG.5at510.

FIGS.6A-6Fillustrates another embodiment of a screen600which can be used with a modular adhesive anchor. Screen600is formed with a plurality of internally actuated radial shutters614aand614b. (The shutters are referred to as “radial” in that they actuate outwardly perpendicular to the axis of the anchor inserted into the screen600and along an outer radius of the screen600.) The shutters are generally planar and arranged into six sides605. More or fewer sides of shutters may be used. Each side is separated by a support rib650. Once again, all of the instances of shutters614are not numbered in order to not obscure the illustration in the figures.FIG.6Ais a perspective view andFIG.6Bis a plan view of this embodiment. It should be understood that screen600may also be fitted with an end cap330at a first end602and abutment structure340at a second end604in a manner similar to that shown with respect to screen300inFIG.3B. End602includes a first set of connection structures comprising posts620to allow attachment of the end cap and a second set of connection structures comprising notches610in second end604which allows connection of an abutment structure and/or allows multiple screens600to be connected to each other.

As shown inFIGS.6A-6E, the shutters614aand614bare of two different sizes and configurations. In alternative configurations, the shutters are the same size and configuration. Shutters614aare generally smaller than shutters614b. Each of shutters614ais placed opposite a corresponding shutter614bon one side of a screen600and alternate along an axial row of one side of the screen600so as to be arranged in an interleaved fashion on each side of screen600. Screen600includes six sides, but more or fewer sides may be used. As shown inFIGS.6E and6F, each shutter includes a hinge side and three free sides. Shutter614aincludes a single hinge613aopposite a free end615awith two free sides617aand618a. Shutter614bincludes two hinges613bopposite a free end615bwith two free sides617aand618a. Each shutter614aand614brotates around its hinge or hinges as an anchor enters the interior of the screen and engages angled cams616a,616bon respective shutters614a,614b. This allows adhesive in the interior of the screen to exit the opening formed by movement of the hinge and be extruded out of the screen into the substrate in which the anchor is being placed.

As shown inFIGS.6C and6D, first end602includes a web625formed by a plurality of generally triangular fingers626at the end of which is formed an opening627. This allows multiple screens to be connected when an anchor is to be provided through multiple cinderblocks, for example. As in previous embodiments, the shutters open to allow adhesive to flow as the anchor is inserted, and closed shutters allow less adhesive (or none) to flow. In addition, the shutters prevent excess adhesive from prematurely flowing out the far end of the screen where the pressure is the highest until the rod is inserted to that depth. Internal shutter cams can be the same height/geometry or different over the length of the screen. This allows adhesives with different viscosities and/or particle size to work in the same screen and controls adhesive flow throughout the entire length of the screen.

Screen600has a generally hexagonal cross-section defined by six sides, each including radial shutters614a,614b. The sides of shutters are separated by supporting ribs650between a leading, distal end602which inserted first into a bore and a trailing or anchor receiving end604. In one embodiment, six supporting ribs are provided but more or fewer ribs, and more or fewer sides having radial shutters, may be used. In other embodiments, some sides need not include radial shutters and may be interleaved with sides containing radial shutters.

FIGS.7A-7Fillustrate another embodiment of a screen700which can be used with a modular adhesive anchor insert.FIG.7Ais a perspective view andFIG.7Bis a plan view of this embodiment. Screen700is formed with a plurality of internally actuated axial shutters714arranged in six rows on screen700, each row separated by a support rib750. All of the instances of the shutters are not numbered in order to not obscure the illustration in the figures. It should be understood that screen700may also be fitted with an end cap330at a first end702and abutment structure340at a second end704in a manner similar to that shown with respect to screen300inFIG.3B. In addition, end702may engage end704to connect multiple ones of screens together. The screen700includes a first set of connection structures comprising posts710on end702to mate with an end cap330, and a second set of connection structures comprising notches720end704to mate with posts710abutment structure340.

As shown inFIGS.7B-7E, the shutters714are generally equally sized and each shutter includes a hinge side and three free sides. Shutter714includes a single hinge713opposite a free end715with two free sides717and718. Each shutter714rotates around its hinge as an anchor enters the interior of the screen and engages angled cams716on a respective hinge713. This allows adhesive in the interior of the screen to exit the opening formed by movement of the hinge and be extruded out of the screen into the substrate in which the anchor is being placed.

Screen700has a generally hexagonal cross-section defined by six sides, each including radial shutters714. The sides of shutters are separated by supporting ribs750between a leading, distal end702which is inserted first into a bore and a trailing or anchor receiving end704. In one embodiment, six supporting ribs are provided but more or fewer ribs, and more or fewer sides having radial shutters, may be used. In other embodiments, some sides need not include radial shutters and may be interleaved with sides containing radial shutters.

FIGS.8A-8Fillustrate another embodiment of a screen800which can be used with an adhesive anchor insert.FIG.8Ais a perspective view andFIG.8Bis a plan view of this embodiment. Screen800is formed with a plurality of externally actuated axial shutters814arranged in eight rows on screen800. All of the instances of the shutters are not numbered in order to not obscure the illustration in the figures. An end cap827is illustrated as attached to a first leading end802of screen800. Screen800may also be fitted with an abutment structure at a second end804in a manner similar to that shown with respect to screen300inFIG.3B. The screen800includes connection structures comprising820on end802and connection structures comprising notches810end804to mate with posts820or, as shown, corresponding notches on an end cap827of screen800. In some implementations, end802may engage end804to connect multiple ones of screens together using notches810and posts820.

As shown inFIGS.8B-8E, the shutters814are generally equally sized and each shutter includes a cam816, hinge side813and three free sides815,817, and818. Shutter814includes a single hinge side813opposite a free end815with two free sides818and818, thereby defining each shutter as having a generally rectangular shape in the axial direction of the screen800. Each shutter814rotates around its hinge as the screen enters bores formed in the substrate or substrate walls to which the screen is inserted. As such, an adhesive within the screen during installation only is extruded in areas adjacent to open regions in the substrate.

Eight shutters814are provided about a circular cross section (FIG.8E), forming a ring of shutters about the cross-section. Each of the eight shutters aligned in one of the five rings of shutters near the first end802about the screen800is separated by a support ring852along approximately half of the screen800adjacent to the first end802. In embodiments, the first five rings of shutters are separated by a support ring852, while the last four rings of shutters are not separated by a support ring. Each shutter in a ring of shutters is separated by either a supporting rib850or a supporting rib855between a leading, distal end804which inserted first into a bore and a trailing or anchor receiving end804. In one embodiment, eight supporting ribs850,855(four each) are provided but more or fewer ribs, and more or fewer shutters in each ring, may be used. In other embodiments, some sides need not include shutters and may be interleaved with sides containing shutters.

FIGS.9A and9Billustrate the opening of the shutters and extrusion of adhesive.FIG.9Aillustrates an assembled insert890including screen800with end cap827and abutment structure828attached. The insert890has been inserted into a first bore944formed in a first web931of a hollow substrate930, extends across an interior cavity910of the hollow substrate930, and is received in second aperture formed in the second opposite web932of the substrate930. As illustrated inFIG.9A, at902,904, shutters814within bores944and945are open, with cams816of any shutters within the bores engaging the sides of bores944,945forcing rotation of each shutter about its hinge side813toward the interior of screen900. This allows adhesive to extrude out of the open shutters within the solid portion of webs931and932(in regions902) to bond with the solid web of the substrate930, and also extend slightly adjacent to the webs931,932to maximize bonding with the solid material. At906, shutters within the interior cavity910in the substrate are closed, preventing, or inhibiting extrusion of adhesive within most of interior cavity910. As a result, when anchor2is inserted into the screen800, extrusion occurs adjacent to the respective webs931,932out of the open shutters within the webs931,932at region902. This is illustrated inFIG.9Bwhich shows screen800and abutment structure828attached (and end cap within web952) As illustrated inFIG.9B, extrusion of adhesive within cavity910a,910boccurs adjacent to the respective webs931a,931b,932a,932b(e.g., at922and926, for example,) when the anchor2is fully inserted into screen800. Thus, shutters914are activated externally to open only in solid portions of base material to allow more adhesive to flow out where the base material is solid and closed shutters located in hollow sections of base material allow less adhesive (or none) to flow.

FIGS.10A-10Eillustrate another embodiment of a screen1000which can be used with an adhesive anchor insert.FIG.10Ais a perspective view andFIG.10Bis a plan view of this embodiment. Screen1000is formed with a plurality of externally actuated radial shutters1014arranged in eight rows on screen1000. All of the instances of the shutters are not numbered in order to not obscure the illustration in the figures. Each of the eight shutters aligned in one of the four rings of shutters near the first end1002about the screen1000is separated by a support ring1052along approximately half of the screen1000adjacent to the first end1002. In embodiments, the first four rings of shutters are separated by a support ring1052, while the last four rings of shutters are not separated by a support ring. An end cap1027is illustrated as attached to a first leading end1004of screen1000. Screen1000may also be fitted with an abutment structure at a second end1002in a manner similar to that shown with respect to screen300inFIG.3B. The screen1000includes connection structures comprising posts1020on end1004and connection structures comprising notches1010end1002to mate with posts1020or, as shown, corresponding notches on an end cap1027of screen1000. In some implementations, end1002may engage end1004to connect multiple ones of screens together using notches1010and posts1020.

As shown inFIGS.10B-10E, the shutters1014are generally equally sized and each shutter includes a cam1016, hinge side1013and three free sides1015,1017, and1018. Shutter1014includes a single hinge side1013opposite a free end1015with two free sides1018and1018, thereby defining each shutter as having a generally rectangular shape in the axial direction of the screen1000. Each shutter1014rotates around its hinge as the screen enters bores formed in the substrate or substrate walls to which the screen is inserted. As such, an adhesive within the screen during installation only is extruded in areas adjacent to open regions in the substrate.

Eight shutters1014are provided about a circular cross section (FIG.10E), forming a ring of shutters about the cross-section. Each hinge side1013is attached to a support rib1050. Each free side1015opposes one of four internal support boss1052. Each of the eight shutters aligned in a ring about the screen1000is separated by a support ring1052. Four support rings1052are provided between the leading end1004and approximately half-way toward the trailing end1002of screen1000. Supporting ribs1050and supporting ribs1052extend between a leading, distal end804which inserted first into a bore and a trailing or anchor receiving end1002. In one embodiment, eight supporting ribs1050,1055(four each) are provided but more or fewer ribs, and more or fewer shutters in each ring, may be used. In other embodiments, some sides need not include shutters and may be interleaved with sides containing shutters.

FIGS.11A and11Bare similar toFIGS.9A and9Band illustrate opening of the shutters and extrusion of adhesive using screen1000in an insert1150.FIG.11Aillustrates an insert1150with screen1000, and end cap1027and abutment structure1028attached. The insert1050has been inserted into a first bore1144formed in a first web1131of a hollow substrate1130, extends across an interior cavity1110of the hollow substrate1130, and is received in second aperture formed in the second opposite web1132of the substrate1130. As illustrated inFIG.11A, at1102, shutters1014within bores1144and1145are open, with cams1016of any shutters within the bores engaging the sides1144,1145of bores forcing rotation of each shutter about its hinge side1013toward the interior of screen1100. This allows adhesive to extrude out of the open shutters within the solid portion of webs1131and1132to bond with the solid web of the substrate1130, and also extend slightly adjacent to the webs1131,1132to maximize bonding with the solid material. At1106, shutters within the voids1110a,1110bare closed, preventing, or inhibiting extrusion of adhesive within most of the web voids1110a,1110b. As a result, when anchor2is inserted into the screen1000, extrusion occurs adjacent to the respective webs1131,1132and in region1102as the shutters are open in this region. This is illustrated inFIG.11Bwhich shows screen1000and abutment structure1028attached (and end cap within web1152) As illustrated inFIG.11B, extrusion of adhesive within cavity1110a,1110boccurs adjacent to the respective webs1131a,1131b,1132a,1132bwhen the anchor2is fully inserted into screen1000. Thus, shutters1114are activated externally to open only in solid portions of base material to allow more adhesive to flow out where the base material is solid and closed shutters located in hollow sections of base material allow less adhesive (or none) to flow. Again, shutters at1124are closed so the adhesive is extruded adjacent to the walls of webs1131,1132at1122and1126, for example.

FIGS.12A-12Fillustrate another embodiment of a screen1200which can be used with an adhesive anchor insert.FIG.12Ais a perspective view andFIG.12Bis a plan view of this embodiment. Screen1200is formed with both a plurality of externally actuated radial shutters1214arranged in four rows on screen1200, and a plurality of apertures1224,1225, and1228. with the apertures provided in both the radial shutters and fixed portions in the screen1200such that they are coincident with the shutters. All of the instances of the shutters and apertures are not numbered in order to not obscure the illustration in the figures. Sections of shutters1214are separated by support rings1250. An aperture1224is provided in each of the radial shutters1214. Apertures1225are provided in fixed wall panels1226. Apertures1228are provided in end cap1227. Two panels1226are adjacent to each radial shutter1214, and two panels1226are separated by one of four support bosses1252. An end cap1227is illustrated as attached to a first, leading end1204of screen1200. In this embodiment, end cap1227is integrally formed with the rest of screen1200through a plastic molding process. Screen1200may also be fitted with an abutment structure at a second end1202in a manner similar to that shown with respect to screen300inFIG.3B. Screen1200includes connection structures comprising posts1220on end1204and connection structures comprising notches1210end1202to mate with posts1220or, as shown, corresponding notches on an end cap1227of screen1200. In some implementations, end1202may engage end1204to connect multiple ones of screens together using notches1210and posts1220.

As shown inFIGS.12B-12E, the shutters1214are generally equally sized and each shutter includes a cam1216, hinge side1213and three free sides1215,1217, and1218. Shutter1214includes a single hinge side1213opposite a free end1215with two free sides1218and1218, thereby defining each shutter as having a generally rectangular shape in the axial direction of the screen1200. Each shutter1214rotates around its hinge1213toward the interior of the screen1200as the screen enters bores formed in the substrate or substrate walls to which the screen is inserted. As such, an adhesive within the screen during installation is extruded all along the length of the screen, but more so in areas adjacent to any web walls and within substrate walls due to open shutters.

Four shutters1214are provided around a circular cross section (FIG.12E). Each hinge side1213is attached to a support rib1250. Each free side1215opposes one of four internal support boss1252. Each of the eight shutters aligned in a ring about the screen1200is separated by a support ring1252. Four support rings1252are provided between the leading end1204and approximately half-way toward the trailing end1202of screen1200. Supporting ribs1250and supporting ribs1252extend between a leading, distal end804which inserted first into a bore and a trailing or anchor receiving end1202. In one embodiment, eight supporting ribs1250,1255(four each) are provided but more or fewer ribs, and more or fewer shutters in each ring, may be used. In other embodiments, some sides need not include shutters and may be interleaved with sides containing shutters.

As noted above, the embodiment ofFIGS.12A-12Fincludes the axial shutters as well as fixed apertures coincident with the apertures. This embodiment provides an advantage as being adaptable for different drilling techniques in the field which might lead to slightly different diameters of a drilled hole in the substrate. Different diameter holes in the substrate will affect how much the shutters can open, and in the case of an extremely oversized hole, the shutters might not open much at all resulting in very little adhesive extruding out of the screen. The addition of the fixed holes allows for some amount of adhesive to come out over the entire length of the screen even if the shutters are not completely opened by the substrate. In this instance, some smaller amount of adhesive can come out the holes over the entire length of the screen and then additional adhesive will come out in the solid parts of the substrate where the shutters are forced open, creating a strong bond in those areas.

FIGS.13A-13Eillustrate another embodiment of a screen1300which can be used with an adhesive anchor insert.FIG.13Ais a perspective view andFIG.13Bis a plan view of this embodiment.FIG.13Cis a view along line13C-13C ofFIG.13A.FIG.13Dis a view along line13D-13D ofFIG.13A.FIG.13Eis an enlarged view of the end portion illustrated inFIG.13A.

Screen1300is formed with a plurality of externally actuated shutters1314which have a limited range with only one open side1318(shown inFIG.3D). The shutters1314are arranged in four rows on screen1300, with a plurality of apertures1325provided in fixed portions in the screen1300. All of the instances of the shutters and apertures are not numbered in order to not obscure the illustration in the figures. Radial sections of shutters1314are separated by support rings1350. Seven support rings1350are provided in one embodiment. In each radial section except section1380nearest end1304, two opposing shutters are provided. In radial section1380near end1304, four shutters1314are provided. Apertures1325are provided in fixed wall panels1326. One of four support bosses1352separate each of shutters1314and fixed wall panels1326. An end cap1327is illustrated as attached to a first, leading end1304of screen1300. In this embodiment, end cap1327is integrally formed with the rest of screen1300through a plastic molding process but attached to the screen by tab1327a. Screen1300may also be fitted with an abutment structure1340at a second end1302in a manner similar to that shown with respect to screen300inFIG.3B. Abutment structure1340is also integrally formed and attached to screen1300by tab1340a. The screen1300includes connection structures comprising posts1320on end1302and connection structures comprising notches1310at end1304to mate with posts1320or, as shown, corresponding notches on an end cap1327of screen1300. In some implementations, end1302may engage end1304to connect multiple ones of screens together using notches1310and posts1320.

As shown inFIGS.13B-13E, the shutters1314are generally equally sized and as shown particularly inFIG.3E, each shutter includes a cam1316, an open side1318and two indented sides1315and1317. A fourth side1319is connected to one of rings1350, thereby defining each shutter as having a generally rectangular shape in the axial direction of the screen1300. Each shutter1314may be depressed inwardly to increase the area at side toward the interior of the screen1300as the screen enters bores formed in the substrate or substrate walls to which the screen is inserted. As such, an adhesive within the screen during installation is extruded all along the length of the screen, but more so in areas adjacent to any web walls and within substrate walls.

Supporting ribs1352extend between a leading, distal end1302which inserted first into a bore and a trailing or anchor receiving end1304. In one embodiment, four supporting ribs1352(four each) are provided but more or fewer ribs, and more or fewer shutters in each ring, may be used. In other embodiments, some sides need not include shutters and may be interleaved with sides containing shutters.

The embodiment ofFIG.13has reduced the number of panels with cams and shutters to reduce the installation effort and prevent too much adhesive from coming out at any single location. The shutters1316are configured to open only along their open edge when the cam is activated whereas other embodiments herein are free on three sides. This provides more flow control and prevents the shutters from accidentally opening outward under pressure where adhesive can escape uncontrolled into void areas of the substrate. In addition, an adhesive is controlled so it can only escape in the solid sections of the substrate. Bores1325are provided in addition to the shutters to allow adhesive to extrude even if the shutters aren't activated properly due to mis-installation.

Notches1310are configured to be much larger than posts1320and sides1321and1323are relatively deep so that any adhesive that flows back up the screen due to flow restrictions in the screen can exit via notches1310. The removable top cap1327may be tethered on the top end1392of the screen1300, and bottom cap1349may or may not be tethered to the end1304of the screen. Bottom cap1340attaches by pressing it onto the notches1310at the bottom of the screen (in a manner similar to assembling several screens together) and removes by twisting if additional screens are needed. Internal axial ribs1352ahelp guide and center the threaded rod and keep it from sagging in horizontal applications. Cams1316act as the activating device for the shutters and also hold the screen in place in the hole so it can't slip out in upwardly inclined and/or overhead holes.

In various embodiments, externally actuated shutter cams can be the same height/geometry or different over the length of the screen to control adhesive flow at distinct locations in the screen. Generally, embodiments herein with axially oriented shutters provide a long lever arm for easy hinging at the connection point, making insertion into the base material easier. Both allow adhesives with different viscosities and/or particle size to work in the same screen and controls adhesive flow throughout the entire length of the screen. Radial oriented shutters generally have a short lever arm to control adhesive flow more precisely but may increase the force for insertion into the base material. Shutter cams can act as barbs to retain the screen in overhead holes.

Each of screens300,400,600,700,800,1000,1200and1300may be fabricated as a single injection molded plastic part, thereby reducing manufacturing costs and significantly and simplify supply chain. Alternative materials may be used to manufacture the screens including sheet metal (e.g. steel, stainless steel, aluminum, or the like), cardboard, or any material of sufficient strength and pliability allow the shutter hinges to work properly, Each of screens300,400,600,700,800,1000,1200and1300are modular in that they may be connected to additional ones of respective anchor screens300,400,600,700,800,1000,1200and1300to provide varying lengths as needed and provide custom lengths. In embodiments, end caps are illustrated as integrally formed as part of the screen and/or separate but attachable to the body of the screen. Each screen embodiment herein may include an attached end cap or separate end cap. Moreover, integrally formed end caps may be removed in the field to allow connections between multiple screens. Although the connection structures are variously described as notches and posts herein, it should be understood that various different types of connection structures may be used with the technology described herein.

Each of screens300,400,600,700,800,1000,1200and1300is referred to herein as being generally cylindrical about a longitudinal axis A passing through the center of each of the cross-sections illustrated inFIGS.3E,4C,7C,8C, and8E. However, certain embodiments (for example screens400,600,700,800,1000,1200and1300) are not entirely cylindrical since they either include sides on which the shutters are formed or include cross-sections defined by the shutters themselves which are not strictly a true circular cross-section. Each of screens300,400,600,700,800,1000,1200and1300is referred to herein as having a tubular shape—a three-dimensional geometric form that resembles a tube or cylinder, characterized by a hollow interior and one or more outer surfaces creating the generally cylindrical shape. Each of screens300,400,600,700,800,1000,1200and1300is generally symmetrical around the longitudinal axis A, with a cross-sectional area consistent along its length.

The terms “top” and “bottom,” “upper” and “lower” and “vertical” and “horizontal” as may be used herein are by way of example and illustrative purposes only and are not meant to limit the description of the invention since the referenced item can be exchanged in position and orientation. Also, as used herein, the terms “substantially” and/or “about” mean that the specified dimension or parameter may be varied within an acceptable manufacturing tolerance for a given application. In one embodiment, the acceptable manufacturing tolerance is ±2.5% of a stated dimension.