Patent Application
20060226662
The invention is directed to the fastening field, particularly to the mounting of articles to a component. Often, for example, in construction of a new house or in rehabilitation of an existing house, there is need to fasten articles to components such as hollow walls and ceilings. Articles may take the form of hangers, bathroom fixtures, pictures, lighting fixtures, pipes, and ducts.
A current technology used to affix an article to a component such as a wall or ceiling is a molly-toggle, which includes a displaceable cap attached to the end of a threaded rod. Once inserted through a hole in a wall, the cap is reoriented to prevent dislodging.
Installation of molly-toggles may be time consuming. Often, as in hanging an article such as a pipe from a component such as a ceiling, there are many to be installed. Also, often there is difficulty in reliably restoring the cap to an orientation where it engages the rear surface of a wall or ceiling. The cap may be stuck in a position not capable of engaging the rear surface and may be immune to the effects of shaking or of gravity.
Further, installation of the molly-toggle may not be stable. The connection between the molly-toggle and the component may not remain secure with passage of time. Because of the nature of most hollow or partition walls or ceilings, most fasteners currently available, such as the molly-toggle, appear strong and well-fitted when initially installed. However, over time, these fasteners tend to loosen, losing strength and becoming weak.
In part, the problem lies with the walls themselves. The initial force holding the molly-toggle is not maintained. Because the thickness of the wall changes over time, the fastener loses it grip on the wall and the articles become loosened. Most hollow or partition walls today are made of soft material and the type of fastener used on this type of wall are expansion fasteners. Because of the nature of the walls, especially dry wall, the grip of the expansion fastener becomes weak over time because the sustaining material around it is inherently weak.
In view of the above difficulties, there is a need for a more reliable and quicker to install means to fasten articles to components.
The needs of the invention set forth above as well as further and other needs and advantages of the present invention are achieved by the embodiments of the invention described herein below.
According to one aspect of the present invention, a fastener of an article to a component includes at least one substantially flexible member and a locking mechanism. Each substantially flexible member includes at least one first portion and a second portion integral with and substantially orthogonal to the at least one first portion. The locking mechanism is capable of being coupled to each substantially flexible member in order to secure the article to the component and the second portion is resiliently deformable with respect to the at least one first portion.
In certain embodiments of the present invention, the second portion may be resiliently deformable with respect to the at least one first portion in a first direction and may be substantially non-deformable with respect to the at least one first portion in a second direction. The first direction may be substantially along a longitudinal axis of the at least one first portion and may be directed away from said second portion and toward the at least one first portion and the second direction may be directed substantially oppositely to said first direction.
In some embodiments of the present invention, the second portion may be elastically alignable with respect to the at least one first portion. In other embodiments of the present invention, the at least one first portion and/or the second portion may be substantially linear. The fastener may further include a third portion integral with the at least one first portion and with the second portion and elastically alignable with respect to the at least one first portion.
In further embodiments of the present invention, each substantially flexible member may further include at least one recess. The recess may be a groove or a hole and the locking mechanism may further include a flap with an edge complementary to a groove.
In certain embodiments of the present invention, the locking mechanism may include a tapped hole or an aperture. In some embodiments of the present invention, the component may be a ceiling, a wall, or a floor or the like. In still other embodiments of the present invention, the article may be a pipe or an electrical fixture.
According to a further aspect of the present invention, a fastener of an article to a component includes at least one substantially flexible member including an at least one first portion, a second portion, and a third portion, and a locking mechanism capable of being coupled to the at least one substantially flexible member to secure the article to the component. The second portion is integral with the third portion and is substantially orthogonal to the at least one first portion and the third portion is integral with the at least one first portion.
In some embodiments of the present invention, the second portion may be resiliently deformable with respect to the at least one first portion in a first direction and may be substantially non-deformable with respect to the at least one first portion in a second direction. The first direction may be substantially along a longitudinal axis of the at least one first portion and may be directed away from said second portion and toward the at least one first portion and the second direction may be directed substantially oppositely to said first direction.
In certain embodiments of the present invention, the second portion may be disengagably couplable to the first portion. In additional embodiments of the present invention, a fourth portion may be integrally coupled to the second portion and may be disengagably coupled to the at least one first portion. The fourth portion may surround the at least one first portion. In other embodiments of the present invention, the third portion may be elastically alignable with respect to the at least one first portion, and the second portion may be elastically alignable with respect to the at least one first portion.
According to another aspect of the present invention, a method for attaching an article to a component includes resiliently deforming a portion of a substantially flexible member with respect to another portion of the substantially flexible member, inserting the resiliently deformed portion through an opening in the component, and engaging the substantially flexible member with a locking mechanism. In some embodiments, the method may further include creating an opening in the component.
In certain embodiments of the present invention, resiliently deforming the portion of the substantially flexible member with respect to the other portion of the substantially flexible member may include elastically aligning the portion of the substantially flexible member with respect to the other portion of the substantially flexible member. In other embodiments of the present invention, engaging the substantially flexible member with the locking mechanism may include inserting the substantially flexible member through the locking mechanism.
Still other embodiments of the present invention may further include pulling the substantially flexible member through the locking mechanism until the locking mechanism couples the article to the component. In additional embodiments of the invention, engaging the substantially flexible member with the locking mechanism may include engaging a flap of the locking mechanism with a recess in the substantially flexible member. The recess may be a groove or an opening.
In still additional embodiments of the present invention, the component may be a wall, floor, or a ceiling or the like. In some embodiments of the present invention, the substantially flexible member may be transportable through the locking mechanism in a single direction.
For a better understanding of the present invention, together with other and further objects thereof, reference is made to the accompanying drawings and detailed description and its scope will be pointed out in the appended claims.
To better understand the concepts and advantages of the various embodiments of the present invention, set forth below is a description of an example of a prior art molly-toggle connector 100 shown in
To install the prior art molly-toggle 100 (
Reference is now made to the various embodiments of the present invention. Embodiments of the present invention may be used in a variety of ways—from fastening of articles or objects 215 to a component 210 such as wall, ceiling, or floor, or the like, to hanging of material to the wall or ceiling, to attaching like and unlike materials together. Articles 215 may include, but are not limited to, fixtures, bathroom fixtures, hooks, hangers, types of lighting fixtures, pipes, etc. Walls and ceilings 210 are generally of the hollow variety, that is, of limited thickness, as is associated with dry wall.
Embodiments of the present invention achieve tight coupling, durable and permanent attachment of articles 215 to a hollow wall, ceiling, or floor or the like 210, or to like or unlike materials. A fastener according to the present invention may be comprised of a substantially flexible member having at least one shaft with the configuration of a cable tie and a top including wing segments, which are integral with and substantially orthogonal to the shaft. The wing segments are resiliently deformable and elastically alignable with respect to the shaft and allow for penetration of a wall 210 and then restoration to a shape that prevents their being pulled out again.
A locking mechanism containing a lock similar to that employed to immobilize cable ties may be used to hold the top in place against the rear surface of the wall 210 and, at the same time, may restrain the top from being pulled out again from the front of the wall 210. Other embodiments may allow for attachment of machine screws or self-tapping screws to the fastener, as may be preferential with other types of fixtures.
Embodiments of the present invention provide a fastener that may more quickly and more reliably mount articles 215 such as light fixtures and pipes to components 210 such as walls, ceilings, and floors than by the means currently represented by the prior art molly-toggle fastener 100 described above. A fastener according to an embodiment of the present invention may include at least one substantially flexible member that may include a shaft or ribbon with recesses, that is, holes or grooves, separated by teeth, molded or embossed into the shaft and a top, which is ordinarily in whole or in part substantially orthogonal to the shaft. Pushing the top into a hole in the component causes the top to be distorted into a furled or compressed configuration. Subsequent passage through the hole results in redeployment of the top to its initial, at least partially, substantially orthogonal orientation, thereby preventing a later reemergence of the top from the component 210. Pulling of the shaft of the substantially flexible member through a locking mechanism causes the fastener to be held in position against the component 210.
Embodiments according to the present invention, using substantially flexible members that include resiliently deformable segments, allow for quicker and more reliable installation than do the existing fasteners such as those employing molly-toggles 100. Once inserted, a fastener according to the present invention remains in place, escape being prevented by the redeployed top. There is no need for reorientation relying on gravity or sensitive to initial cap position. Top redeployment is automatic following penetration of the hole by the top.
Elastic restoration forces generated during attachment maintain firm attachment of the article to the component 210 even as the component 210 texture evolves over time. Further, the quality of the attachment is not subject to sensitivity to the amount of torque applied to a fastener that may lead to damage to a portion of the component 210 underlying a fastener such as a molly-toggle 100.
Passage of the shaft 315 through the aperture 312 results in sequential engagement and disengagement of the flap 314 with the grooves 325. When the top 320 of the substantially flexible member 305 is immobilized, pulling of the shaft 315 through the locking mechanism 310 proceeds until the pulling force generates an equal and opposite restoring elastic force in the shaft 315. The pulling force may be removed and the elastic force preserved by the immobility of the locking mechanism 310 with respect to the shaft 315 resulting from the interaction of the flap 314 and the groove 325.
Next, wing segments 505 of the top 320 are bent away from the wall by, for example, squeezing between fingers, or by insertion of the top 320 with sufficient force to resiliently deform or elastically align the top 320 by bending the wing segments 505 of the top 320 into substantial alignment with the shaft 315 (Step 415 and
In such a resiliently deformed condition, the top 320 is inserted through the holes 205 or openings in the article 215 and component 210 or wall until the top 320 has proceeded far enough to allow the wing segments 505 of the top 320 to redeploy to their original orientation, that is, nearly perpendicular or substantially orthogonal to the shaft 315 (Step 420 and
The top 320 of the substantially flexible member 305 is made of an elastic-type of material, that is, a resiliently deformable material, which permits the wing segments 505 of the top 320 to be bent into substantial alignment with the shaft 315 and then, once the force that caused the bending is removed, to allow the wing segments 505 to assume their former configuration, substantially orthogonal to the shaft 315, and to remain substantially nondeformable when pulled in the substantially opposite direction. The deployed wing segments 505 resist an attempt to be bent or deformed in a direction substantially aligned with the longitudinal axis 340 of the shaft 315 and directed from the shaft 315 toward the top 320. Consequently, extraction of the top 320 through the holes 205 in a direction substantially opposite to the direction of insertion is prevented during subsequent tightening of the locking mechanism 310.
In the final phase of the attachment process, the end 510 of the shaft 315 of the substantially flexible member 305 distal from the top 320 engages a locking mechanism 310, by, in some embodiments, insertion through the locking mechanism 310 (Step 425), and the locking mechanism 310 is pushed toward the component 210. Engagement may be a result of a flap 314 of the locking mechanism 310 engaging a recess 325, including a groove or opening, in the substantially flexible member 305. The shaft 315 is then pulled firmly until the article 215 and the component 210 are firmly coupled or bound by compression between the locking mechanism 310 and the deployed wing segments 505 of the top 320 (Step 430 and
Compression is preserved even as pulling of the shaft 315 ceases by the combination of the elastic stretching imposed on the resilient deformable flexible member 305 and the immobility resulting from the interaction of the grooves 325 of the shaft 315 with the flap 314 of the locking mechanism 310. Retraction of the button 310 is generally not possible without damage to the shaft 315 or to the locking mechanism 310.
In other embodiments of the present invention, the substantially flexible member 305 may be presented first to a hole 205 in the component 210. After insertion of the top 320 of the substantially flexible member 305 through the hole 205 in the component 210, the shaft 315 of the substantially flexible member 305 may be inserted through a hole 205 in the article 215. The locking mechanism 310 may then be engaged with the shaft 315.
The insertion process is similar to the process illustrated in
Upon passage through the holes 205 in the article 215 and component 210, the resiliency and elasticity of the wing segments 505 and connecting segments 610 allows redeployment of the top 320 in such a manner as to prevent the top 320 from being pulled out if the shaft 315 is pulled away from the component 210 or article 215 (
The wing segments 505 may be disengagably couplable with the shaft 315. In some embodiments, contact between the wing segments 505 and the shaft 315 may be absent before, during, and after deployment, as where the space 705 between the inner ends 710 of the wing segments 505 and the shaft 315 is sufficiently large. In other embodiments, contact between the wing segments 505 and the shaft 315 may be absent before and after deployment, but present during deployment as the wing segments 505 slide back and forth along the shaft 315. In further embodiments, contact between the wing segments 505 and the shaft 315 may be present before, during, and after deployment as the inner ends 710 of the wing segments 505 maintain contact with the shaft 315 in sliding along the shaft 315.
The connecting segments 610 may be integral with the shaft 315 and wing segments 505 of the top 320 and increase resistance of the deployed top 320 to pull through. The connecting segments 610 may also be resiliently deformable and elastically alignable with respect to the shaft 315.
The insertion process is similar to the process illustrated in
Upon passage through the holes 205 in the article 215 and component 210, the resiliency and elasticity of the wing segments 505 and the connecting segments 610 allow redeployment of the top 320 in such a manner as to prevent the top 320 from being pulled out if the shaft 315 is pulled away from the component 210 or article 215 (
As in the sliding triangular-top fastener 700, the outer ends 605 of the wing segments 505 of the top 320 of the substantially flexible member 305 are integral with the connecting segments 610 connecting to an extension 615 of the shaft 315 or stem. The wing segments 505 are not integral with the shaft 315. The wing segments 505 and the connecting segments 610 are resiliently deformable or elastically alignable with respect to the shaft 315.
The loop 905 may be disengagably couplable with the shaft 315. In some embodiments, contact between the loop 905 and the shaft 315 may be absent before, during, and after deployment, as where the opening 910 of the loop 905 is sufficiently large. In other embodiments, contact between the loop 905 and the shaft 315 may be absent before and after deployment, but present during deployment as the loop 905 slides back and forth along the shaft 315. In further embodiments, contact between the loop 905 and the shaft 315 may be present before, during, and after deployment as the loop 905 maintains contact with the shaft 315 in sliding along the shaft 315. The loop 905 maintains the inner ends 710 of the wing elements 505 substantially in the vicinity of the shaft 315 during insertion of the substantially flexible member 305.
The connecting segments 610 may be integral with the shaft 315 and wing segments 505 of the top 320 and increase resistance of the deployed top 320 to pull through. The connecting segments 610 may also be resiliently deformable and elastically alignable with respect to the shaft 315.
The insertion process is similar to the process illustrated in
Upon passage through the holes 205 in the article 215 and component 210, the resiliency and elasticity of the wing segments 505 and the connecting segments 610 allow redeployment of the top 320 in such a manner as to prevent the top 320 from being pulled out if the shaft 315 is pulled away from the component 210 or article 215 (
Although the invention has been described with respect to various embodiments, it should be realized that this invention is also capable of a wide variety of further and other embodiments within the spirit and the scope of the appended claims.
This application claims priority from U.S. Provisional Application Ser. No. 60/663,447, filed Mar. 21, 2005, and, in addition, is a continuation-in-part of U.S. application Ser. No. 11/242,093, filed on Oct. 3, 2005 and claiming priority from U.S. Provisional Application Ser. No. 60/636,647, filed on Dec. 17, 2004. Each aforementioned application is incorporated herein by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 60663447 | Mar 2005 | US | |
| 60636647 | Dec 2004 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 11242093 | Oct 2005 | US |
| Child | 11385185 | Mar 2006 | US |
