Patent Description:
The Bang-It ® + product is a cast-in-place anchor assembly available for purchase and aspects of the present invention are conceived to improve upon this product.

<CIT> relates to threaded anchors for poured concrete metal deck floors. An anchor has a shaft and a head. The shaft is inserted through an aperture in a flat plate. A sleeve is held in place on the body of the shaft on the side of the plate opposite to the head, by press fit.

According to the present invention there is provided a cast-in-place anchor assembly according to claim <NUM>. Optional features are defined in dependent claims <NUM> to <NUM>.

According to an aspect of the present disclosure there is provided a cast-in-place anchor assembly for suspending objects below a metal deck after concrete pouring and concrete setting, the anchor assembly comprising: an anchor body having a threaded opening extending partially through it along an axis; a sleeve mounted to the anchor body and defining a sleeve opening which extends away from the anchor body along said axis, the sleeve also having a flexible portion that is configured to elastically flex upon insertion of the sleeve through a hole in a metal deck that is narrower than the width of the flexible portion; a support defining a supporting channel through which the anchor body extends and that is configured to permit sliding movement, but restrict tilting movement, of the support relative to the anchor body; and a spring for biasing the support along the anchor body towards the sleeve so that, in use, opposite sides of a metal deck are clamped between the support and the flexible portion of the sleeve.

The support may have a planar surface portion for engaging a metal deck in use and the supporting channel may extend away from the planar surface portion in a direction along the length of the anchor body.

The supporting channel may define an inner surface corresponding in shape to the outer surface of the anchor body.

The supporting channel may be reinforced by reinforcing features of the support, optionally by a plurality of ribs.

The anchor body is provided with at least one feature on its outer surface which the sleeve cooperates with for mounting to the anchor body and wherein the support has features biased against the anchor body which are configured, during manufacture of the anchor assembly, to cooperate with the at least one feature provided on the outer surface of the anchor body for retaining the support and spring in connection with the anchor body prior to mounting of the sleeve to the anchor body.

The features of the support which are biased against the anchor body may be inwardly extending clips.

Features of the sleeve that cooperate with the at least one feature provided on the outer surface of the anchor body for mounting the sleeve to the anchor body may each have a ramped surface for assisting in decoupling of the sleeve from a mould during manufacture.

The at least one feature provided on the outer surface of the anchor body may be a recess, which is optionally an annular recess.

The anchor body may be partially received within the sleeve, the sleeve having an edge portion in engagement with an edge of the anchor body that defines an entrance to the threaded opening for assisting in correctly mounting the sleeve to the anchor body during manufacture.

The flexible portion of the sleeve may comprise a plurality of elastically deformable fingers.

The fingers may have a variable thickness along their respective lengths.

The fingers may decrease in thickness along their respective lengths.

The sleeve may comprise a cover section inside the sleeve opening adjacent the entrance thereto such that a threaded bolt can be inserted partially along the sleeve opening before engaging the cover section.

The cover section may comprise a plurality of inwardly extending flaps.

The sleeve may define a plurality of slots adjacent the entrance to the sleeve opening thereby defining a plurality of castellations and the flaps may extend inwardly from respective castellations.

Embodiments will now be described by way of non-limiting example with reference to the accompanying drawings in which:.

A cast-in-place anchor assembly <NUM> for suspending objects below a metal deck after concrete is poured onto the metal deck is illustrated in <FIG> and <FIG>. An anchor body <NUM> has a head portion <NUM> and a shank portion <NUM>. A threaded bore <NUM> extends partially through the shank portion <NUM> along an axis <NUM>. Additionally an annular recess <NUM> is provided in the outer surface of the anchor body <NUM>. In use when concrete has set around the anchor body <NUM> (see <FIG>) a load can be suspended from it via threaded engagement with the internal bore <NUM>. Other features of the anchor assembly <NUM> assist in mounting the anchor body <NUM> to a metal deck and holding it in place prior to concrete pouring and during concrete setting.

For instance a sleeve <NUM> cooperates with the annular recess <NUM> for mounting the sleeve <NUM> to the anchor body <NUM>. A sleeve opening <NUM> extends through the sleeve <NUM> away from the anchor body <NUM> in alignment with the internal threaded bore <NUM>. An outwardly protruding flexible portion <NUM> of the sleeve <NUM> is configured to elastically flex upon insertion of the sleeve <NUM> through a hole in a metal deck that is narrower than the width W of the flexible portion <NUM>. Between the sleeve <NUM> and head portion <NUM> of the anchor body <NUM> is provided a support <NUM> and a spring <NUM> which biases the support <NUM> towards the sleeve <NUM>. The spring <NUM> is conical whereby the narrow end contacts the head portion <NUM> of the anchor body <NUM> and the widest part contacts with the support <NUM>. As mentioned when the sleeve <NUM> is urged through a hole in a metal deck <NUM> which is narrower than the width W of the flexible portion <NUM>, then the flexible portion <NUM> will deform to enable insertion through the hole but will return to its original shape after passing therethrough. From <FIG> it will be apparent that following such insertion the action of the spring <NUM> biasing the support <NUM> towards the sleeve <NUM> causes the metal deck <NUM> to be clamped between the support <NUM> and the flexible portion <NUM> of the sleeve <NUM>. This maintains the anchor body <NUM> in an upright orientation relative to the metal deck <NUM> during concrete pouring and setting.

Features of the anchor assembly <NUM> will now be described in more detail.

The support <NUM> has a planar portion <NUM> which extends outwardly along a direction perpendicular to the aforementioned axis <NUM>, wherein the shank portion <NUM> of the anchor body <NUM> extends through an opening <NUM> in the planar portion <NUM>. An upper planar surface portion 38a faces the head portion <NUM> of the anchor body <NUM> and lower planar surface portion 38b faces the sleeve <NUM>. The lower planar surface portion 38b is configured for substantially flush engagement with a metal deck in use (see <FIG>).

Looking at <FIG> in particular the planar portion <NUM> of the support <NUM> is substantially rectangular and has a plurality of openings <NUM> extending through it adjacent the corner sections thereof. These openings <NUM> are provided so that the support <NUM> can be fixed to a metal deck by fasteners (e.g. screws) if the hole in the deck through which the anchor assembly <NUM> is caused to extend in use is wider than the width W of the outwardly protruding flexible portion <NUM> of the sleeve <NUM>, in which case the anchor assembly <NUM> cannot clamp the metal deck between the support <NUM> and outwardly protruding flexible portion <NUM> of the sleeve <NUM> like in <FIG>.

The aforementioned opening <NUM> through the planar portion <NUM> co-aligns with the centre of the planar portion <NUM>. With continued reference to <FIG> a guide portion <NUM> of the support <NUM> is provided around the upper rim of the opening <NUM> and extends upwards away from the upper planar surface portion 38a along the axis <NUM>. More specifically this guide portion <NUM> defines a supporting channel 34a having an inner surface <NUM> with a cross section that corresponds in shape to the outer cross section the shank <NUM> of the anchor body <NUM>. In the particular embodiment illustrated the shank <NUM> is cylindrical and so the supporting channel 34a is correspondingly cylindrical and configured to receive the shank <NUM>. This enables sliding movement of the support <NUM> relative to the shank <NUM> of the anchor body <NUM> but restricts tilting movement of the support <NUM> relative to the shank <NUM> of the anchor body <NUM>.

Additionally, a plurality of ribs <NUM> are provided for reinforcing the supporting channel 34a to restrict flexing of the guide portion <NUM>. The ribs <NUM> extend between the upper planar surface portion 38a and the exterior surface of the guide portion <NUM>. In more detail the ribs <NUM> extend a distance x along the upper planar surface portion 38a and a distance y along the exterior surface of the guide portion <NUM> (see <FIG>), wherein y is identical to the length of the guide portion <NUM>. In other words, the ribs <NUM> extend entirely along the length of the guide portion <NUM> for reinforcing its integrity along its entire length. Looking at <FIG> in particular, the ribs <NUM> are circumferentially distributed around the guide portion <NUM> such that adjacent ribs are equi-distant from each other and wherein the distance x is such that the spring <NUM> can surround the ribs <NUM> and engage the upper surface portion 38a. In other words the widest end of the spring <NUM> is configured to surround the arrangement of ribs <NUM> so that the spring <NUM> can urge against the upper surface portion 38a of the support <NUM> (see <FIG>).

The above mentioned supporting channel 34a and rib <NUM> arrangement restricts tilting movement of the anchor body <NUM> relative to the upper surface of a metal deck once the anchor assembly <NUM> is installed but prior to concrete pouring. This thus reduces the likelihood of construction workers causing anchor bodies <NUM> to be misaligned upon accidently kicking them while working on a metal deck prior to concrete pouring.

Referring now to <FIG> the support <NUM> includes an annular seat <NUM> around the lower rim of the opening <NUM> that extends downwards away from the lower surface portion 38b along the axis <NUM>. This annular seat <NUM> has an inner surface 44a with a cross section that corresponds in shape to the outer cross section the shank <NUM> of the anchor body <NUM>. A plurality of clips <NUM> extend from the annular seat <NUM> which in the embodiment illustrated resemble a plurality of castellations and so will be referred to as castellations hereafter. The castellations <NUM> are circumferentially distributed around the annular seat <NUM> such that adjacent castellations <NUM> are equi-distant from each other. Furthermore the castellations <NUM> are configured to curve inwardly across the face of the opening <NUM> and supporting channel 34a through which the shank <NUM> of the anchor body <NUM> extends.

It is here mentioned that the inner surfaces <NUM>, 44a of the guide portion <NUM> and the annular seat <NUM> are contiguous, that is they extend into one another. In another manner of speaking the guide portion <NUM> and annular seat <NUM> can be thought of as separate sections of a cylindrical portion, an upper part of which (i.e. the guide portion <NUM>) extends from the upper rim of the opening <NUM> and the lower part of which (i.e. the annular seat <NUM>) extends from the lower rim of the opening <NUM>.

The purpose of the above mentioned castellations <NUM> is as follows. During manufacture of the anchor assembly <NUM> in <FIG>, the spring <NUM> is provided around the shank <NUM> of the anchor body <NUM>. Subsequently the support <NUM> is caused to surround the shank <NUM> of the anchor body <NUM>. Compressing the spring <NUM> by urging the support <NUM> along the length of the shank <NUM> loads the spring <NUM> with potential energy. However, when the tips of the castellations <NUM> align with the recess <NUM> in the outer surface of the anchor body <NUM> they extend into the recess <NUM>. The castellations <NUM> and recess <NUM> thus cooperate to resist the compressed spring <NUM> from urging the support <NUM> out of engagement with the anchor body <NUM>. This enables the combined arrangement of the anchor body <NUM>, spring <NUM> and support <NUM> to be moved around during the manufacturing process without separating. In a factory for instance the combined arrangement of the anchor body <NUM>, spring <NUM> and support <NUM> could potentially be passed onto an operative tasked with coupling sleeves <NUM> to such arrangements and quality checking the final arrangements.

To enable coupling of the sleeve <NUM> to the anchor body <NUM>, the sleeve <NUM> is provided with a plurality of inwardly extending protrusions <NUM> as illustrated in <FIG>. The inwardly extending protrusions <NUM> each include a ramped surface 48a on a side facing the outwardly protruding flexible portion <NUM>. The inwardly extending protrusions <NUM> also each include a step portion 48b on a side facing an entrance <NUM> to the sleeve opening <NUM>. During manufacture of the anchor assembly <NUM> in <FIG> (once the anchor body <NUM>, spring <NUM> and support <NUM> are coupled together) the shank <NUM> of the anchor body <NUM> is inserted, via the outwardly protruding flexible portion <NUM>, into the sleeve <NUM>. Engagement of the sleeve <NUM> and support <NUM> urges the support <NUM> further along the shank <NUM> away from the recess <NUM>. When the inwardly extending protrusions <NUM> of the sleeve align with the annular recess <NUM> they extend into it. The step portions 48b cooperate with the recess <NUM> to resist subsequent separation the sleeve <NUM> from the shank <NUM> of the anchor body <NUM>. More specifically due to the spring <NUM> being compressed it will urge the support <NUM> into engagement with the sleeve <NUM>, however, cooperation between the inwardly extending step portions 48b and the recess <NUM> resist the sleeve <NUM> separating from the shank <NUM>.

The sleeve <NUM> is additionally provided with an annular blocking edge <NUM> that is configured to engage an edge of the anchor body <NUM> defining an entrance to the threaded opening <NUM> for blocking the sleeve <NUM> from being pushed too far along the shank <NUM> during manufacture. To explain this more fully reference is made to <FIG>. The structure of the sleeve <NUM> heretofore described is such that it has a primary portion <NUM> and a head portion <NUM>. The primary portion <NUM> is tubular, wherein one end of the primary portion <NUM> forms the aforementioned entrance <NUM> to the sleeve opening <NUM> (described in more detail below) and the other end of the primary portion <NUM> defines the annular blocking edge <NUM>. <FIG> illustrates how the annular blocking edge <NUM> cooperates with the edge <NUM> of the anchor body <NUM> defining an entrance to the threaded opening <NUM> for the purpose of blocking the sleeve <NUM> from being pushed too far along the shank <NUM> during manufacture. It will be appreciated from the foregoing that the inwardly extending protrusions <NUM> of the sleeve <NUM> described in connection with <FIG> extend into the annular recess <NUM> in the outer surface of the shank <NUM> when the annular blocking edge <NUM> of the sleeve cooperates with the edge <NUM> of the anchor body <NUM>. Movement of the anchor body <NUM> and sleeve <NUM> relative to each other is thus restricted in either direction along the axis <NUM>.

Looking back at <FIG> a series of arms <NUM> couple the head portion <NUM> of the sleeve <NUM> to the primary portion <NUM> of the sleeve <NUM>, the head portion <NUM> having an opening extending through it which is wider than that extending through the primary portion <NUM> of the sleeve <NUM>. This is to enable the head portion <NUM> to surround the shank <NUM> of the anchor body <NUM>, wherein from the drawings it will be apparent that the inwardly extending protrusions <NUM> described in connection with <FIG> are provided on an inner surface of the head portion <NUM>.

In some embodiments the sleeve <NUM> has three arms <NUM> that are circumferentially distributed, although more or fewer such arms <NUM> could be used instead.

The height of the arms <NUM> relative to the outer surface of the primary portion <NUM> of the sleeve <NUM> increases with increased distance along the axis <NUM> towards the head portion <NUM> of the sleeve <NUM>. The arms <NUM> thus define a ramped portion <NUM> for assisting in inserting the sleeve <NUM> through an opening in a metal deck in use. An internal surface of each ramped portion <NUM> defines part of the heretofore described annular blocking edge <NUM> (see <FIG>). A distal section <NUM> of each respective arm <NUM>, having a flat outer surface, extends into a respective notch <NUM> of the head portion <NUM>.

It is here mentioned that the inwardly extending protrusions <NUM> described in connection with <FIG> are provided on the sections of the head portion <NUM> between the respective notches <NUM>, which resemble a plurality of circumferentially distributed teeth portions and so will be referred to hereafter as teeth <NUM>. A gap <NUM> exists between the inner surface of the teeth <NUM> and the outer surface of the primary portion <NUM> of the sleeve <NUM> which the teeth <NUM> partially extend over. This enables the teeth <NUM> to flex relative to the outer surface of the primary portion <NUM> of the sleeve <NUM> which makes it easier to couple the sleeve <NUM> to the anchor body <NUM> during manufacture. In particular when the shank <NUM> of the anchor body <NUM> is inserted into the sleeve <NUM> as heretofore described, before the annular groove <NUM> aligns with the inwardly extending protrusions <NUM> the above mentioned teeth <NUM> are caused to flex outwards. However when the inwardly extending protrusions <NUM> do align with the annular groove <NUM> in the shank <NUM> the teeth <NUM> flex back inwards.

With continued reference to <FIG> the outwardly protruding flexible portion <NUM> of the sleeve <NUM> extends from the head portion <NUM>. A plurality of circumferentially arranged elastically deformable curved fingers <NUM> form the outwardly protruding flexible portion <NUM> of the sleeve <NUM>. In the embodiment illustrated, together the outwardly protruding flexible portion <NUM> and head portion <NUM> of the sleeve <NUM> resemble a crown. The fingers <NUM> have a variable thickness along their respective lengths. In particular the fingers decrease in thickness along their respective lengths, which gives them more flexibility compared to fingers of a similar nature that have the same thickness along their respective lengths. The distal end of the fingers <NUM> may terminate in an edge <NUM> rather than continuing to a point, which reduces the risk of user injury.

With yet further reference to <FIG> the sleeve <NUM> comprises a cover section <NUM> inside the entrance <NUM> to the sleeve opening <NUM>. A plurality of slots <NUM> extend from the entrance <NUM> to the sleeve opening <NUM> along the sleeve <NUM> in a direction parallel with the axis <NUM>, thereby defining a plurality of circumferentially distributed castellations <NUM>. The cover section <NUM> is formed by a plurality of flaps <NUM> which extend inwardly from the respective castellations <NUM>. Since the flaps <NUM> are located inwardly a distance z from the entrance <NUM> to the sleeve opening (i.e. the distal part of the sleeve <NUM>), in use a threaded bolt can be inserted partially along the sleeve opening <NUM> before engaging the cover section <NUM>. This assists a user in aligning a threaded bolt with the sleeve opening <NUM> before pushing it along the sleeve <NUM> into threaded engagement with the internal threaded bore <NUM> of the anchor body <NUM>. The respective flaps <NUM> bend when a threaded bolt is urged against them. Furthermore, the slots <NUM> enable the castellations <NUM> to flex relative to the main part of the sleeve <NUM> so that when a threaded bolt is pushed through the cover section <NUM> it is not solely the flexing of the flaps <NUM> that enables the bolt to pass through the cover section <NUM> but the combined flexing of the flaps <NUM> and castellations <NUM>, which reduces the likelihood of the flaps <NUM> snapping in use. Prior to such insertion of a threaded bolt however the flaps <NUM> restrict the ingress of material along the sleeve <NUM> into contact with the internal bore <NUM> of the anchor body <NUM>.

Claim 1:
A cast-in-place anchor assembly (<NUM>) for suspending objects below a metal deck after concrete pouring and concrete setting, the anchor assembly comprising:
an anchor body (<NUM>) having a threaded opening (<NUM>) extending partially through it along an axis (<NUM>);
a sleeve (<NUM>) mounted to the anchor body (<NUM>) and defining a sleeve opening (<NUM>) which extends away from the anchor body (<NUM>) along said axis (<NUM>), the sleeve (<NUM>) also having a flexible portion (<NUM>) that is configured to elastically flex upon insertion of the sleeve (<NUM>) through a hole in a metal deck that is narrower than the width of the flexible portion (<NUM>);
a support (<NUM>) defining a supporting channel (34a) through which the anchor body (<NUM>) extends and that is configured to permit sliding movement, but restrict tilting movement, of the support (<NUM>) relative to the anchor body (<NUM>); and
a spring (<NUM>) for biasing the support (<NUM>) along the anchor body (<NUM>) towards the sleeve (<NUM>) so that, in use, opposite sides of a metal deck are clamped between the support (<NUM>) and the flexible portion (<NUM>) of the sleeve (<NUM>),
wherein the anchor body (<NUM>) is provided with at least one feature on its outer surface which the sleeve (<NUM>) cooperates with for mounting to the anchor body (<NUM>) and characterised in that the support (<NUM>) has features biased against the anchor body (<NUM>) which are configured, during manufacture of the anchor assembly, to cooperate with the at least one feature provided on the outer surface of the anchor body (<NUM>) for retaining the support (<NUM>) and spring (<NUM>) in connection with the anchor body (<NUM>) prior to mounting of the sleeve (<NUM>) to the anchor body (<NUM>).