1. Field of the Invention
This invention relates broadly to fasteners. More particularly, this invention relates to fastener assemblies for hanging objects on wall board.
2. State of the Art
As described in published Patent Application No. 2007/0235622, the contents of which are hereby incorporated by reference, gypsum wallboard, also known as drywall, SHEETROCK®, plasterboard, gib board, rock lath, and gypsum board became popular for home construction following World War II and have for the most part replaced plaster walls previously common in residential and commercial construction. The wallboard is comprised of a pair of sheathings or liners on both sides of a gypsum based core. The liner material can be paper, polymers, or other sheet materials. Gypsum wallboard, in the United States, is available in thicknesses of ¼ inch, ⅜ inch, ½ inch, ⅝ inch, ¾ inch and 1 inch with ½ inch being the most commonly used.
For gypsum core wallboard, it is known that when anchoring objects force distribution between the anchor and the wallboard is critical as gypsum core will crush easily under concentrated localized shear forces. Conventional attachment means, such as a nail, are not effective in drywall except for holding very modest weights due to the concentration of force. Weight from an object suspended on the nail tends to crush the gypsum and rip the paper immediately below the nail. Any such displacement by the nail loosens and weakens the attachment. The moment caused by the weight about the generalized pivot region of the nail generally provides a dislodgement force component of the nail that is increased as the nail is loosened and approaches and extends below horizontal. Such nails that are solely in gypsum wallboard are clearly not usable for attaching appurtenances such as shelves, bathroom accessories, or any object that will be manipulated on the wall.
More substantial attachment to conventional gypsum wallboard is accomplished by connectors that utilize clamping members that pierce the wallboard and provide a clamping action, typically by way of a screw, between the inner and outer surfaces of the gypsum wallboard. Such hangers provide very secure attachment but are relatively complicated, usually with two or more moving parts and can be tedious to install. Also, where there is a stud or no cavity behind the wallboard, such connectors won't work. Moreover, these connectors cause significant damage to the wall when removed and may be very difficult to remove. Other gypsum wallboard connectors utilize an expanding cylinder or conical insert that provides significantly more surface area contact with the wallboard. These also utilize a plurality of components, and take several distinct operations to install. If removed, there is significant damage to the wallboard.
Therefore, it is advantageous to have a fastening assembly which is relatively simple to use and manufacture and which can be utilized in conjunction with a variety of fastening devices such as nails, screws, expandable hollow wall fasteners, molly fasteners, etc., in order to increase the load carrying capabilities of such fasteners. It is also advantageous to have a fastening assembly which is simple, quick and easy to use and install.
The prior art discloses many-different types of fastening devices or assemblies for mounting objects on sheet rock walls and the like. However, so far as is known, none of the prior art devices resolve all of these problems in a simple, effective and yet highly advantageous manner as in the present invention discussed herein.
It is therefore an object of the invention to provide a novel fastening assembly for retaining an object to a wall.
It is also an object of the invention to provide a fastening assembly which significantly increases the load carrying capabilities of a fastener.
It is another object of the invention to provide a universally adaptable fastening assembly for use with various fasteners.
It is a further object of the invention to provide a fastening assembly which is easy to remove.
It is yet another object of the invention to provide a fastening assembly which minimizes damage to the wall when removed.
It is yet another object of the invention to provide a fastening assembly which has a relatively simple construction and is quick and easy to use and install.
It is yet another object of the invention to provide a fastening assembly which is simple, easy and inexpensive to manufacture.
Certain of the foregoing and related objects are readily attained according to the present invention by the provision of a fastener assembly for mounting an object on a wall, comprising a substantially planar member having at least one ledge extending substantially perpendicular therefrom, said member being configured to permit at least a portion of said planar member to lie flush against the wall with said at least one ledge inserted at least partially through the wall and means for fastening said member to the wall.
Advantageously, said at least one ledge has a length which is less than a thickness of the wall. Alternatively, said at least one ledge has a length which is equal to or greater than the thickness of the wall. In a preferred embodiment, said member has a through-bore. Preferably, said through-bore has an axis which forms an acute angle relative to said member. Alternatively, said through-bore has an axis which is substantially perpendicular to said member. Desirably, said means for fastening said member to the wall comprises a nail which is receivable within said through-bore. In the alternative, said means for fastening said member to the wall comprises a molly fastener and a screw receivable within said through-bore.
Furthermore, it is also desirable that said means for fastening said member to the wall comprises an adhesive layer disposed on said back side of said member. Alternatively, said member has a front side and a back side and said means for fastening comprises a curved, support member having a tip projecting outwardly and rearwardly from the back side of said member which, when fully mounted, projects through the wall with its tip resiliently contacting a concealed surface of the wall. Preferably, said member defines a bottom edge and said at least one ledge is located on said bottom edge of said member. In another embodiment, said member defines a top edge and said at least one ledge is located on said top edge of said member. Alternatively, said member defines a top edge and a bottom edge and said at least one ledge is disposed between said top and bottom edges.
It is also desirable that the fastener assembly further comprise means for supporting the object on the wall. In another embodiment, said planar member has means for supporting the object on the wall. In a further embodiment, said means for fastening also serves to support the object on the wall.
Certain of the foregoing and related objects of the invention are also readily attained by the provision of a method of installing a fastener assembly for mounting an object on a wall comprising the steps of providing a fastener assembly comprising a substantially planar member having at least one ledge extending substantially perpendicular therefrom, said member being configured to permit at least a portion of said planar member to lie flush against the wall with said at least one ledge inserted at least partially through the wall and means for fastening said member to the wall inserting said at least one ledge at least partially into the wall so that at least a portion of said member lies flush against the wall; and securing said member to the wall via said means for fastening.
Preferably, said at least one ledge has an edge to permit it to pierce the wall during said inserting step. Most desirably, said fastening assembly further comprises means for supporting the object. Advantageously, the method further comprises the step of securing the object to said means for supporting the object.
The preferred embodiments of the present invention will now be more particularly described by way of example with reference to the accompanying drawings.
Other objects and features of the present invention will become apparent from the detailed description considered in connection with the accompanying drawings, which disclose several embodiments of the invention. It is to be understood that the drawings are to be used for the purpose of illustration only and not as a definition of the limits of the invention.
Turning now to
The lower ledge 24 may be sharp, or having a tapered or pointed end as illustrated, to facilitate penetration of the wall 60. Alternatively, the ledge 24 may be blunt and the wall 60 scored before installation. According to this embodiment, the through-bore 22a is angled (e.g. forms an acute angle relative to the plate) so that the nail 30 enters the wall 60 at an angle and the head of the nail acts as the “hook” to support an object (not shown). As illustrated, the ledge 24 is substantially perpendicular to the plate 20a and is dimensioned so that it extends at least partially into the wall 60 but does not puncture the inside face 64 of the wall. The ledge 24 also includes a flat bottom edge and an angled top edge. It is preferable that the ledge extend ¾ of the width of the wall, however, it can be dimensioned so that it is inserted to other depths. The ledge 24 may be manually pressed into the wall 60 or with the aid of a hammer.
When installed, the plate 20a lies flush against the exposed surface 62 of the wall 60 with the ledge 24 extending into the wall 60. The plate 20a serves as a crutch, support or means to spread out the load on the wall 60 and, thereby, increasing the load carrying abilities of the nail 30, so that the nail 30 can support heavier objects than it could without plate 20a.
Referring now to
According to the second embodiment, the molly fastener 34 is inserted into a hole in the wall 60. The plate 20b is then aligned so that the hole 22b is coaxial with the molly fastener 34. The ledge 24 can be sharp to facilitate penetration of the wall and can be either pressed into the wall manually or with the aid of a hammer. Alternatively, the ledge 24 can be blunt and the wall scored prior to pressing in the blunt ledge. The screw 32 is inserted through a hook 40 and then through the hole 22b into the molly fastener 34. The screw 32 is then turned into the molly fastener 34 to secure hook 40 to the wall. An object (not shown) can be secured to hook 40. It can be appreciated that another object besides hook 40 can be secured to the wall 60.
The plate 20b serves to increase the load carrying abilities of molly fastener 34 and screw 32 by spreading out the load on the wall 60, so that heavier objects can be secured to the wall 60 than could be without plate 20b. It can be appreciated that the present invention can be adapted for a variety of fastening devices such as, screws, nails, molly fasteners, expandable hollow wall fasteners, etc.
Alternate embodiments of the fastening assemblies of present invention are shown in
The fastening assembly 50 also includes a conventional molly fastener 53 formed on the back side of the planar plate 54 in alignment with the through-bore. Fastening assembly 50 also includes a ledge 52 extending outwardly from planar plate 54. Ledge 52 is spaced apart from the bottom edge 56 of the planar plate 54. However, it can be appreciated that the location of the ledge can be varied such as located at the bottom edge 56 (not shown). As can be seen in
In
A fastening assembly 70 according to the fourth embodiment is illustrated, in
In
In regard to the embodiment of the fastening assembly 80 shown in
In order to secure the fastener 80 to wall 60, as shown in
Turning now to
In regard to the seventh embodiment of the fastener 100 shown in
As seen in
As seen in
A ninth embodiment of a fastening assembly 120 is shown in
As can be appreciated, the construction of all of the embodiments of the present invention allows for the fastening assemblies to support particularly heavy objects to a wall, due to the L-shaped member having a ledge projecting outwardly therefrom, which is at least partially received in the wall. The support of such heavy loads is not presently accomplishable with the prior art fasteners described. It can be appreciated that such L-shaped configuration and ledge of the present invention can be adapted to other types of fasteners to increase their overall load carrying capabilities.
As can be appreciated, the means for fastening an object to the fastening assemblies can vary. Particularly, the means for fastening can serve the dual function of both fastening the member to the wall and for securing an object to the wall, such as the nail 30, shown in
There have been described and illustrated herein several embodiments of a fastener support and methods of installing it. While particular embodiments of the invention have been described, it is not intended that the invention be limited thereto, as it is intended that the invention be as broad in scope as the art will allow and that the specification be read likewise. Thus, while the fastener supports have been illustrated as generally rectangular, they could be configured as triangles or other polygons or even be circular or oval. Furthermore, although the ledges are illustrated as having a pointed configuration, it can have a blunt edge or a square shaped edge and the wall scored prior to the insertion into the wall.
Additionally, the location and number of ledges utilized can vary. While it is preferable that the ledges extend approximately ¾ of the width of the wall, the length of the ledge can vary so that it extends to other depths into the wall or even through the wall so that the end thereof projects outwardly from the concealed side of the wall. Moreover, although the fasteners are primarily intended for use with gypsum wall board and the like, it may be possible to adapt the fastening assemblies to use with walls made of other materials. It will therefore be appreciated by those skilled in the art that yet other modifications could be made to the provided invention without deviating from its spirit and scope as claimed.
This application claims benefits from U.S. Provisional Patent Application No. 61/379,778, filed Sep. 3, 2010, the contents of which are hereby incorporated herein by reference.
Number | Date | Country | |
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61379778 | Sep 2010 | US |