Abstract:
A method for manufacturing an anchor device and the product thereof. The method includes providing an elongated mold having an axial hole, a plurality of grooves extending radially from the axial hole, and an enlarged receiving space formed adjacent to the second end of the axial hole; disposing a metal shaft in the axial hole of the mold with an upper end of the metal shaft extending into the receiving space of the mold; injecting a molten plastic material into the mold around the metal shaft in order to fill the grooves and the receiving space; moving a forming die into the receiving space of the mold to depress the plastic material in the receiving space; and retracting the forming die from the mold and removing the integrally formed anchor device from the mold.

Description:
FIELD OF THE INVENTION 
     This invention relates to a method for manufacturing an anchor device and the product thereof, more particularly to a method for manufacturing an anchor device having an insert with a plurality of rib members extending radially therefrom and an attachment seat integrally formed on an upper end of the insert. 
     BACKGROUND OF THE INVENTION 
     Referring to FIG. 1, a conventional anchor device  1  is shown to comprise an insert  11  and a clamping seat  10  connected to an upper end of the insert  11 . The insert  11  is adapted to be rammed into the ground  2  while the clamping seat  10  is exposed from the ground  2 . A mounting post  4 , for example, of a mailbox  3  is inserted into and is clamped by the clamping seat  10  in order to be supported above the ground  2 . The conventional anchor device  1  is made of a zinc-plated metal material and is manufactured according to the following steps: 
     (1) Forming a trapezoidal first zinc-plated metal plate (A 1 ) by means of a cutting process, as shown in FIG.  2 ( a ). 
     (2) Bending the first zinc-plated metal plate (A 1 ) along its centerline to form an angled plate, as shown in FIG.  2 ( b ). 
     (3) Welding together the bent portions of two angled plates (A 1 ) of FIG.  2 ( b ) at a few points (B) in order to form a cross-shaped member with four ribs (A 3 ), as shown in FIG.  2 ( c ). 
     (4) Forming an elongated second zinc-plated metal plate (A 2 ), as shown in FIG.  2 ( d ). 
     (5) Bending the second zinc-plated metal plate (A 2 ) into a clamping seat  10  with four connecting portions  100 , as best illustrated in FIG.  2 ( e ). 
     (6) Welding the edges of the rib members (A 3 ) on the connecting portions  100  of the clamping seat  10  at points (B) in order to form the conventional anchor device  1 , as best illustrated in FIG.  2 ( f ). 
     The conventional anchor device  1  suffers from the following disadvantages: 
     1. The zinc-plated metal plate is expensive. Therefore, the manufacturing cost of the conventional anchor device  1  is relatively high. 
     2. The manufacturing process of the conventional anchor device  1  is very complicated. 
     3. The welding points (B) are liable to corrode due to weather factors, thereby resulting in eventual separation of the components of the conventional anchor device  1 . 
     Therefore, the conventional anchor device  1  has a relatively short service life. 
     SUMMARY OF THE INVENTION 
     The object of the present invention is to provide a method for manufacturing an anchor device which can be manufactured at a relatively low cost and which has a good weather resistance and a relatively long service life, as well as to provide the product thereof. 
     According to one aspect of the present invention, an anchor device having an elongated insert with a plurality of rib members extending radially therefrom may be manufactured according to the following method: 
     (a) providing an elongated mold having an axial hole formed along a longitudinal axis thereof, a plurality of grooves extending radially from the axial hole, each of the grooves having a radial width which increases gradually in a direction from a first end to a second end of the axial hole, and a enlarged receiving space formed adjacent to the second end of the axial hole; 
     (b) disposing a metal shaft such as an metal shaft having a tapered end and a head end in the axial hole of the mold so that the head end of the metal shaft extends into the receiving space of the mold; and 
     (c) injecting a molten plastic material into the mold around the metal shaft in order to fill the grooves and the receiving space so as to form the insert of the anchor device. 
     In one embodiment the attachment seat is an open box that can receive, for example, a pole, and can clamp the pole in place (i.e., a clamping seat). According to one aspect of the present invention, the clamping seat may be manufactured at an upper end of the anchor device according to the following method: 
     (a) same as above 
     (b) same as above 
     (c) same as above 
     (d) moving a forming die into the receiving space of the mold to depress the plastic material in the receiving space so as to form an open area surrounded by sidewalls; 
     (e) retracting the forming die from the mold; and 
     (f) removing the integrally formed anchor device from the mold. 
     In another embodiment the attachment seat may be a block preferably with a hole therethrough for attaching, for example, a rope (i.e., an anchoring seat). According to one aspect of the present invention, the anchoring seat may be manufactured at an upper end of the anchor device according to the following method: 
     (a) same as above 
     (b) same as above 
     (c) same as above 
     (d) moving a forming die into the receiving space of the mold to depress the plastic material in the receiving space so as to form a block with a hole therethrough; 
     (e) retracting the forming die from the mold; and 
     (f) removing the integrally formed anchor device from the mold. 
     According to another aspect of the present invention, the anchoring seat may be manufactured at an upper end of the anchor device according to the following method: 
     (a) same as above 
     (b) disposing a metal shaft having a tapered end and a head end in the axial hole of the mold so that the head end of the metal shaft extends into the receiving space of the mold, the head end including a block with a hole therethrough on top of a circular head; 
     (c) injecting a molten plastic material into the mold around the metal shaft in order to fill the grooves and the receiving space so as to form the insert of the anchor device and coat the circular head and the block; 
     (d) removing the integrally formed anchor device from the mold. 
     According to one embodiment of the present invention, an anchor device comprises: 
     (a) an elongated insert which is made of a plastic material and which has upper and lower ends, and a plurality of rib members extending radially therefrom, each of the rib members having a radial width which increases gradually in a direction from the lower end to the upper end of the insert; 
     (b) an attachment seat which is made of a plastic material and which is integrally connected to the upper end of the insert and upper edges of the rib members; and 
     (c) a metal shaft embedded longitudinally in the insert, the metal shaft having an upper end which extends into the attachment seat, and a lower end which extends out of the lower end of the insert. 
     According to another embodiment of the invention, the attachment seat is a clamping seat that includes an opening surrounded by sidewalls that can be clamped together. 
     According to another embodiment, the attachment seat may be an anchoring seat that includes a block with a hole therein. The block may be plastic or may be metal (e.g., an extension of the metal shaft) coated in plastic. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Other features and advantages of this invention will become apparent in the following detailed description of the preferred embodiments of this invention with reference to the accompanying drawings, in which: 
     FIG. 1 is a schematic view illustrating how a conventional anchor device is used to support the mounting post of a mailbox; 
     FIG.  2 ( a )- 2 ( f ) are schematic views illustrating the manufacturing process of the conventional anchor device; 
     FIG. 3 is a fragmentary, exploded schematic view illustrating an elongated mold for manufacturing one embodiment of an anchor device having a clamping seat according to a method of the present invention; 
     FIG. 4 is a fragmentary, exploded schematic view illustrating a metal shaft disposed in the mold of FIG. 3 when the anchor device is manufactured according to a method of the present invention; 
     FIG. 5 is a cross-sectional view of the mold of FIG. 3 at an axial hole in which the metal shaft is disposed when the mold is in a closed position; 
     FIG. 6 is a cross sectional view of the mold of FIG. 3 at a receiving space in which a forming die is disposed when the mold is in the closed position; 
     FIG. 7 is perspective view of a preferred embodiment of the anchor device having a clamping seat according to the present invention; 
     FIG. 8 is a side view of a preferred embodiment of the anchor device of FIG. 7; 
     FIG. 9 is a perspective view of another preferred embodiment of the anchor device of FIG. 7, according to the present invention. 
     FIG. 10 is a fragmentary, exploded schematic view illustrating an elongated mold for manufacturing a preferred embodiment of the anchor device having an anchoring seat, according to a method of the present invention; 
     FIG. 11 is a fragmentary, exploded schematic view illustrating a metal shaft disposed in the mold of FIG. 10 when the anchor device is manufactured according to a method of the present invention; 
     FIG. 12 is a perspective view of another preferred embodiment of an anchor device having an anchoring seat, according to the present invention; 
     FIG. 13 is a side view of the anchor device of FIG. 12; 
     FIG. 14 is a lower view of the anchor device of FIG. 12, showing another embodiment of the metal shaft; and 
     FIG. 15 is a perspective view of the anchor device of FIG. 12 illustrating how a rope can be put through the anchoring seat. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring to FIGS. 3 and 4, one embodiment of an anchor device of this invention is fabricated by means of an injection molding mold  5  as described below. The mold  5  has an axial hole  50  formed along a longitudinal axis thereof, and a plurality of (in this embodiment, four) grooves  51  extending radially from the axial hole  50 . Each of the grooves  51  has a radial width which increases gradually in a direction from a first end  500  to a second end  501  of the axial hole  50 , and an enlarged receiving space  52  formed adjacent to the second end  501  of the axial hole  50 . 
     A metal shaft  6  is disposed in the axial hole  50  of the mold  5 , as best illustrated in FIG.  4 . The lower end  60  of the metal shaft  6  is tapered and extends out of the first end  500  of the axial hole  50 . The upper end  61  of the metal shaft  6  is a circular head that extends into the receiving space  52  of the mold  5 . An annular gap  62  is formed between the metal shaft  6  and the internal face defining the axial hole  50  of the mold  5  when the mold  5  is closed, as best illustrated in FIG.  5 . 
     A molten plastic material is injected into the annular gap  62  of the mold  5  around the metal shaft  6  in order to fill the grooves  51  and the receiving space  52 . A forming die  53  is moved into the receiving space  52  of the mold  5 , as best illustrated in FIG. 6, in order to depress the plastic material in the receiving space  52 . After the plastic material is cooled and hardened, the forming die  53  is retracted from the receiving space  52  of the mold  5 . An integrally formed anchor device  7  is thus obtained and is removed from the mold  5 . 
     Referring to FIG. 7, the resulting anchor device  7  is shown to comprise an elongated insert  70  and a clamping seat  72 . The insert  70  is formed as a hollow tube in the annular gap  62  of the mold  5  and has lower and upper ends  700 ,  701  which are formed correspondingly in the first and second ends  500 ,  501  of the axial hole  50  of the mold  5 . A plurality of rib members  71 , which are formed in the grooves  51  of the mold  5 , extend radially from the insert  70 . Each of the rib members  71  has a radial width which increases gradually in a direction from the lower end  700  to the upper end  701  of the insert  70 . 
     The clamping seat  72 , which is formed in the receiving space  52  by means of the forming die  53 , is integrally connected to the upper end  701  of the insert  70  and upper edges  711  of the rib members  71 . The clamping seat  72  has a generally rectangular hollow body which has notch  721  formed at a corner thereof, as best illustrated in FIG. 8, and which has a spaced pair of engaging lugs  720  that extend outwardly from the corner. The engaging lugs  720  have pairs of aligned holes  722  formed therein. A plurality of bolts and nuts  8  engage the aligned holes  722  in order to force the engaging lugs  720  toward one another when being tightened, thereby enabling the clamping seat  72  to clamp firmly a post(not shown), for example a mailbox mounting post, inserted therein. 
     The metal shaft  6  is embedded longitudinally in and is connected firmly to the insert  70 . The circular head upper end  61  of the metal shaft  6  is embedded in the clamping seat  72 , thus facilitating positioning of the center of gravity of the anchor device  7  when ramming the anchor device  7  into the ground. The tapered lower end  60  of the metal shaft  6  extends out of the lower end of the insert  70 , thus facilitating the ramming action of the anchor device  7  into the ground. 
     FIG. 9 shows another preferred embodiment of an anchor device according to the present invention. In this embodiment, the structure of the anchor device is similar to that of the anchor device  7  of the aforementioned embodiment, except that each of the upper edges of the rib members  71  has a thickened portion  710  formed at the juncture of a corresponding one of the rib members  71  and the clamping seat  72  in order to increase the structural strength of the rib members  71 . 
     Referring to FIGS. 10 and 11, another embodiment of an anchor device of this invention is fabricated by means of an injection molding mold  30  as described below. The mold  30  has an axial hole  32  formed along a longitudinal axis thereof, and a plurality of (in this embodiment, four) grooves  33  extending radially from the axial hole  32 . Each of the grooves  33  has a radial width which increases gradually in a direction from a first end  321  to a second end  322  of the axial hole  32 , and a receiving space  35  formed adjacent to the second end  322  of the axial hole  32 . A shaft  36  is contained in the receiving space  35  so as to form a hole within the receiving space  35 . 
     A metal shaft  40  is disposed in the axial hole  32  of the mold  30 , as best illustrated in FIG.  11 . The lower end  41  of the metal shaft  40  is tapered and extends out of the first end  321  of the axial hole  32 . The upper end  42  of the metal shaft  40  is a circular head that extends into the receiving space  35  of the mold  30 . 
     An annular gap is formed between the metal shaft  40  and the internal face defining the axial hole  32  of the mold  30  when the mold  30  is closed. A molten plastic material is injected into the annular gap of the mold  30  around the metal shaft  40  in order to fill the grooves  33  and the receiving space  35 . The shaft  36  ensures that the molten plastic within the receiving space  35  has a hole formed therein, so as to form an anchoring seat. An integrally formed anchor device  50  is thus obtained and is removed from the mold  30 . 
     Referring to FIGS. 12 and 13, the resulting anchor device  50  is shown to comprise an elongated insert  51  and an anchoring seat  55 . The elongated insert  51  is formed as a hollow tube in the annular gap of the mold  30  and has lower and upper ends  401 ,  402 . A plurality of rib members  54  extend radially from the elongated insert  51 . Each of the rib members  54  has a radial width which increases gradually in a direction from the lower end  401  to the upper end  402  of the insert  51 . 
     The anchoring seat  55  is integrally connected to the upper end  402  of the insert  51  and upper edges of the rib members  54 . The anchoring seat  55  has a lower circular surface  53  upon which a block  56  is formed. The block  56  preferably contains a hole  561  therein. Formed on top of the block  56  is an upper circular surface  57 . As illustrated, the upper circular surface  57  is larger than the block  56  but is preferably smaller that the lower circular surface  53 . 
     The metal shaft  40  is embedded longitudinally in and is connected firmly to the insert  51 . Additionally, the circular head upper end  42  of the metal shaft  40  is embedded in lower circular surface  53  of the anchoring seat  55 , thus facilitating positioning of the center of gravity of the anchor device  50  when ramming the anchor device  50  into the ground. The tapered lower end  41  of the metal shaft  40  extends out of the lower end  401  of the insert  51 , thus facilitating the ramming action of the anchor device  50  into the ground. 
     An alternative embodiment of the anchoring seat entails utilizing a modified metal shaft  900 . The modified shaft includes a tapered lower end  901  and a head end  902 . The head end includes a circular plate  903  that has a block  904  formed thereon. The block  904  preferably has a hole  905  formed therein. Utilizing this modified shaft allows the anchoring seat to be made of metal such as iron and only be coated with plastic. This embodiment is best illustrated in FIG.  14 . The upper circular surface is still made of plastic so as to provide a larger surface to drive the anchor device  50  in the ground. 
     Advantageous, a cap (not shown), such as a plastic cap, is formed so as to fit over the upper circular surface  57 . This cap is to protect the upper circular surface  57  as the anchoring device is driven into the ground. 
     Similarly to the embodiment depicted in FIG. 9 but not illustrated in a separate figure, the rib member  54  of the anchor device  50  may also include a thickened portion formed at the juncture of a corresponding one of the rib members  54  and the anchoring seat  55  in order to increase the structural strength of the rib members  54 . 
     Referring to FIG. 15, a connection means  999  such as a rope, a bar, etc. may be threaded through the hole  561  and used to anchor, tie down or support various items such as tents, trees, etc. (not shown). 
     It should be noted that the molds of any of the embodiments described above may have clamps, rods, or other holding means to hold the metal rod in place. Thus, the anchor device will have voids where the plastic did not form because of these clamps. These holes need to be sealed in order to prevent the possibility of water getting in the anchor device and causing the metal rod to rust. The holes can be sealed with, for example, an epoxy material. 
     It is noted, that since the anchor device of the present invention is made of a plastic material by means of an injection molding process, the manufacturing costs of the anchor device can be reduced dramatically. In addition, rusting will not occur when the anchor device is in use, thereby improving the durability of the anchor device. 
     It should also be noted that the length of the elongated insert and thus the metal rod, depends on the use of the anchor device. As would be apparent to those skilled in the art the more weight that is being supported by the anchor device with the clamping seat or the more force being held in place by the anchor device with the anchor seat the longer the elongated insert and thus the metal rod will be. 
     While the present invention has been described in connection with what is considered the most practical and preferred embodiments, it is understood that this invention is not limited to the disclosed embodiments but is intended to cover various arrangements included within the spirit and scope of the broadest interpretations and equivalent arrangement.