The present invention relates generally to mounting devices and systems. More particularly, the present invention relates to a non-invasive mounting system that may be used for a variety of applications such as repairing drywall and mounting an object to a wall.
Drywall, also commonly referred to as wall board or gypsum panel and commonly sold under the brand name SHEETROCK®, is often used in homes, buildings, and other structures. Drywall is essentially a chalk-like gypsum pressed between layers of paperboard. Typically, sheets of drywall are nailed or screwed to a structure's framing with a plurality of sheets “hung” next to each other in an abutted fashion to form a wall. The gaps between the drywall sheets are then filled with joint compound or vinyl spackling commonly referred to as “mud.” When the mud dries the surface may be sanded and painted to provide a finished look.
While drywall provides an aesthetically pleasing look, it is easily damaged when it is struck by an object and therefore often needs repair. For example, drywall can be damaged when it is struck by a doorknob when opening a door or when it is struck by piece of furniture when moving the furniture. In addition, portions of drywall are often removed in order to gain access to the wall's interior such as to make repairs to plumbing, wiring, or other structures housed within the wall.
One method of patching drywall holes is to place paper or some other material over the hole and apply mud atop the material. A disadvantage of this technique is that the material generally produces a raised portion that must be heavily sanded. Furthermore, such techniques only work for small holes and are inapplicable for larger holes because such a repair technique does not provide adequate support. Thus, for larger holes it may be necessary to insert a replacement piece or “plug” of drywall into the hole. For example, a user may create a drywall “plug” by cutting a piece of drywall in the shape of the hole and then nailing or screwing the plug to framing positioned behind the hole. While this technique may work when there is framing located directly behind the hole that provides support for the plug, holes are often located where there is no framing on which to mount the plug. In addition, oftentimes there is some other structure, such as plumbing or wiring, that prevents the simple attachment of the plug to the framing. Thus, providing sufficient support to the plug can prove difficult.
The prior art discloses various devices and methods for repairing holes in walls. For example, U.S. Pat. No. 4,620,407 entitled “Method For Drywall Patching” discloses a drywall repair kit comprising a template having a saw guide, repair plug, and patching compound. The template is used to cut out a portion of the drywall about the damaged area, with the drywall being at a sloped angle or contoured inwardly. The repair plug has a peripheral sloped wall edge and is dimensioned for being insertable into the cutout with its sloped wall edges abutting the sloped or contoured wall portions defining the prepared drywall cutout. The repair plug may be mounted within the drywall cutout such that its outermost surface is slightly recessed below the surface of the drywall. Patching compound may be applied over the repair plug to form a relatively flat smooth wall surface.
U.S. Pat. No. 4,989,385 to McCullough entitled “Device For Repairing a Hole in a Plasterboard Wall” discloses a device for plasterboard repair that is formed of a flat relatively thin, stiff coverboard, and an insulation board secured by adhesive to the coverboard rear surface. The insulation board is dimensioned less than the coverboard, leaving a clear space around the peripheral of the coverboard rear surface. The insulation board is dimensioned to be received in the hole to be repaired, and screws or adhesive are used to secure the coverboard rear surface peripheral clear space to the wall to thereby retain the insulation board in the hole with the coverboard completely covering the hole.
U.S. Pat. No. 4,715,151 entitled “Plasterboard Repair Kit” discloses a repair kit for use in patching a hole in a plaster wall that includes a substantially cube-shaped inflatable member comprised of a flexible but substantially inelastic plastic. The front wall of the inflatable member includes a valved opening therein through which the device can be inflated and an interior retainer extends between the front and rear walls to prevent them from bulging after inflation. In its deflated form, the device is inserted into the cavity behind a hole in a plaster or plasterboard wall and is then inflated utilizing a carbon dioxide cartridge in a holder having a nozzle inserted into the opening. After inflation, the inflated member acts as a seal behind the hole so that the hole can then be filled with plaster or other patch material.
U.S. Pat. No. 5,555,691 to Nguyen entitled “Drywall Repair System” discloses a drywall repair kit which includes a hollow tubular guide and a solid plug for fitting into the guide. The solid plug includes adhesive on its insertion end to secure the plug in place. After the plug is secured the guide is removed. The length of the plug is only slightly less than the stud space between drywall sheets plus the thickness of the drywall.
While the devices of the prior art are suited for their intended purposes, they are complex and often require special equipment. They also often require that paper or other materials be provided atop the wall surface, thus producing an undesirable raised portion. In addition, the prior art methods can be expensive, or limited to repairing holes of a particular size. Furthermore, repairs by the methods of the prior art can result in a weakened area of the wall. What is needed is a simple, efficient, easy, and cost-effective method of repairing holes in drywall that is scalable for use to a variety of different hole sizes and produces a strengthened repair area.
In addition to repairing drywall as discussed above, it is often desirable to mount an object to a surface. For example, it is often desirable to mount a picture, painting, sign, plate, or other object to a wall.
While it is known to mount an object to a wall using invasive hardware, such as by driving a nail into the wall to provide structure upon which to hang the picture, or screwing a bracket into the wall, such invasive mounting methods are often undesirable. For example, to mount a picture on a wall using a nail, a user pounds the nail through the wall surface using a hammer. But the piercing of the wall can damage structure behind the wall such as plumbing or wiring. In addition, the wall may be made of material, such as plaster or wood that may be susceptible to cracking or splitting when a nail is driven through it; or the material may be difficult to penetrate. Alternatively, the wall may be part of a sealed container, such as a sealed drum, inflatable structure, or the like which could be pierced by the nail, thereby releasing the container's contents. Furthermore, the use of a nail is a rather noisy process that may be inappropriate for some situations, such as when a user desires to mount an object at night when a nearby neighbor is asleep. Finally, many prior art systems do not provide sufficient support for mounting objects on non-vertical surfaces such as ceilings or in environments in which the object may be subjected to other forces, such as wind.
In the cases where brackets are used to mount an object, it is often difficult to mate the bracket mounted on the wall to the object to be mounted. Bracket systems often require that a bracket be mounted on a wall and on the object to be mounted. For example, the object to be hung may lack the wire, hook, bracket, or other structure that is to be hung over the nail, thereby necessitating a complicated process by which a user must provide the object with such structure. This may prove especially difficult in situations where the object to be mounted is not conducive to receiving such devices. For example, it would not be possible to screw in a mounting bracket to a porcelain plate. In addition, many bracket systems used for mounting display objects, such as commonly done with plates, at least partly cover the front surface of the object, resulting in an unappealing look that distracts from the object.
U.S. Pat. No. 6,286,802 to Munson, et al., entitled “Hanger System Having Bubble Level Insert” discloses a hanger system comprising a first track attachable to an object and a second track attachable to a wall. The second track includes a level which indicates a level orientation of the track. The first track and the second track can cooperatively engage one another such that the object will be secured in a level orientation on the wall with the first and second tracks. While fit for its intended purpose, the Munson Patent requires the mounting of the brackets using screws and it is not applicable to wall repair.
Thus, there is a need for an apparatus that allows a user to both repair walls and mount objects. There is a further need for an apparatus and system that provides for the repair of a hole in drywall where there is no framing support at the hole. There is also a need for an apparatus and system for repairing walls that is readily scalable to repair different sized holes. There is also a need for a drywall repair device and system that minimizes the amount of mudding and sanding required to produce a finished surface. There is also a need for a drywall repair device and system that result in a sturdy repair that requires a minimal number of tools.
There is a further need for a mounting system that is non-invasive and may be used on a variety of surfaces. There is a further need for a mounting system which does not require additional tools such as a hammer or drill, which can be used with a variety of objects of different materials, such as picture frames, plates, and signs, and which does not result in excessive noise. There is also a need for an apparatus and system that allows for the simple, inexpensive, and easy mounting of an object to both vertical and non-vertical surfaces.
The present invention provides a mounting apparatus and system that allow for quick and easy drywall repair as well as the non-invasive mounting of an object. In an exemplary embodiment of the invention, the mounting apparatus, called a Barry stick after its inventor, comprises an elongated support member having an attaching portion for attaching the support member to a surface. The support member has a sufficient degree of rigidity to provide support to objects attached thereto. The attaching portion can include an exposable adhesive layer provided on a surface of the support member. The exposable adhesive layer may be covered by a removable protective layer which protects the exposable adhesive layer prior to use. When the mounting apparatus is ready for use, the protective layer is removed to expose the exposable adhesive layer. An exemplary embodiment of the mounting apparatus of the present invention therefore comprises: an elongated support member having a front face; an exposable adhesive layer provided atop said front face; and a removable protective layer provided atop said exposable adhesive layer.
In an exemplary method of the invention for repairing a hole in drywall, the mounting apparatus can be used for mounting a drywall plug within the hole. For example, the mounting apparatus may be positioned on the rear surface of the drywall so that a first portion of the adhesive layer is attached to the rear surface of the drywall and a second portion of the adhesive layer extends over the hole, to define a receiving surface for receiving a drywall plug inserted into the hole. A drywall plug of a size slightly smaller than the hole may then be inserted into the hole and pressed against the second portion of the adhesive layer so that the plug adheres to the support member. An exemplary method of repairing a hole in drywall comprises: removing a removable protective layer of a mounting apparatus to expose an adhesive attaching layer; attaching a first portion of the adhesive attaching layer to the back surface of the wall adjacent to a hole so that a second portion of the adhesive surface extends over the hole thereby defining a drywall plug receiving surface; and inserting a drywall plug into the hole so that the plug attaches to the drywall plug receiving surface.
In another exemplary embodiment of the invention, the mounting apparatus may be used for the non-invasive mounting of an object to a surface. In addition to the support member and attaching portion discussed above, the mounting apparatus may further include an engaging portion adapted to engage another mounting apparatus. In one exemplary embodiment, the engaging portion may be an angled face of the support member that is adapted to engage the angled face of another mounting apparatus. An exemplary embodiment of the mounting apparatus comprises: an elongated support member having a front face; an exposable adhesive layer provided atop said front face; a removable protective layer provided atop said exposable adhesive layer; and at least one engaging surface adapted to engage a second mounting apparatus. Thus, one mounting member may be attached to an object that is to be mounted and another mounting member attached to the mounting surface to which the object will be mounted. The object can then be mounted by engaging the engaging surfaces of the first and second mounting apparatus. An exemplary method of mounting an object in accordance with the invention comprises: attaching a first mounting apparatus to an object to be mounted, said mounting apparatus having an attaching portion and an engaging portion; attaching a second mounting apparatus to a surface to which the object will be mounted, said second mounting apparatus comprising a support member having an attaching portion and an engaging portion; and engaging the engaging portion of the first mounting apparatus to the engaging portion of the second mounting apparatus to mount the object.
In another exemplary embodiment of a mounting system of the present invention, multiple mounting apparatus may be used to define a receiving track for receiving another mounting apparatus. For example, a first and second mounting apparatus may be attached to a wall and arranged in a parallel-spaced-apart relationship to define a receiving track. A third mounting apparatus may be attached to an object to be mounted to the wall and the support member of the third mounting apparatus inserted into the receiving track so that the engaging surface of the inserted mounting apparatus engages the engaging surfaces of the first and second mounting apparatus. This arrangement allows for the easy mounting of an object, as well as its removal and replacement with another object by simply sliding the mounted object's mounting member along the mounting track. Of course, instead of the mounting track being defined on the wall it could be defined on the object to be mounted and the third mounting apparatus provided on the wall. In addition, multiple tracks and inserting members may be created with the mounting apparatus of the present invention and may be provided on a variety of objects and surfaces such as picture frames, plates, walls, ceilings, etc. In other exemplary embodiments of the invention, an end cap may be provided to provide support at the ends of the track to prevent the object from sliding along the track.
For purposes of teaching and not limitation, in the exemplary embodiments the objects mounted include a picture frame and a plate, but it is contemplated that other objects could be similarly mounted. Likewise, whereas in the exemplary embodiments the mounting surface is shown as being a wall, it will be understood that the invention is not so limited but may be used with a variety of surfaces.
Still further, the mounting member may be size adjustable. For example, the desired size of the mounting apparatus may vary with the size of the object to be mounted. To assist a user in obtaining a mounting apparatus of desired size the mounting apparatus may be provided with measurement indicia and perforations. For example, perforations may be provided at predetermined intervals such as every inch so as to assist a user in quickly and easily separating the mounting apparatus at those points. A user can place the mounting member against the object to determine a desirable size and then separate the member at the corresponding perforation. The mounting system may also be provided with apertures for receiving nails or fasteners if desired.
The system of the present invention thus provides a simple, quick, and inexpensive method for mounting objects that requires no tools and is non-invasive. The present invention allows for the mounting of a plurality of objects, and allows for the easy replacement of a mounted object. The mounting apparatus of the present invention is also capable of interior and exterior use.
Generally speaking, the apparatus, systems and methods taught herein are directed to mounting devices and systems. By applying what is taught herein, objects can quickly and easily be mounted to a desired mounting surface without the need of tools or an invasive technique. In addition, a simple and efficient method for repairing drywall is shown.
As required, exemplary embodiments of the present invention are disclosed. These embodiments are provided as examples of various embodiments of the invention and it will be understood that the invention may be embodied in alternative forms. The figures are not to scale and some features may be exaggerated or minimized to show details of particular elements, while related elements may have been eliminated to prevent obscuring novel aspects. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention. For purposes of teaching and not limitation, the illustrated embodiments are directed to repairing drywall and mounting a picture frame or plate to a wall but it will be understood that other structures could be similarly repaired and a variety of objects could be mounted to a variety of surfaces using what is taught herein.
Referring now to the drawings, wherein like numerals represent like elements throughout,
Turning to
The mounting apparatus 100 may now be installed. As shown in
With the mounting apparatus 100 now in place as shown in
Turning to
As previously mentioned and as shown in
As shown in
In the previous example, the picture frame 701 was mounted to the vertical surface 821 of a wall 803. However, the mounting apparatus 100 of the present invention may be used to mount objects on non-vertical surfaces as well. To provide additional support when mounting an object, mounting apparatus may be arranged on a first surface so as to define a receiving track adapted to receive a mounting apparatus attached to another surface. For example, as shown in
For example, as shown in
Because the mounting system is non-invasive and the mounting system is provided behind the object mounted, the system is ideal for mounting fragile display objects such as plates 1205 shown in
Furthermore, the mounting apparatus may be used as part of the display and may be provided in different colors. It is also contemplated that the mounting apparatus may be provided of different thickness and height. For example, standard thicknesses of ¼″, ½″ and ¾″ sizes may be provided (see
The mounting apparatus may be provided in a variety of sizes. To assist in properly sizing a mounting member, as shown in
As also shown in
The above-described and illustrated embodiments of the present invention are examples of implementations set forth for a clear understanding of the principles of the invention. Variations and modifications may be made to the above-described embodiments, and the embodiments may be combined, without departing from the scope of the following claims. It should be recognized that elements of the exemplary embodiments may be altered by persons skilled in the art without departing from the spirit and scope of the invention. For example, as disclosed in the specification the mounting apparatus has two engaging surfaces so that it can be easily engaged with another mounting apparatus without worry as to whether one of the mounting apparatus is upside down, but it is contemplated that a single engaging surface could be provided on the mounting apparatus.
This application is a division of and claims the benefit of priority under 35 USC 120 of U.S. application Ser. No. 11/406,761, filed Apr. 19, 2006.
Number | Date | Country | |
---|---|---|---|
Parent | 11406761 | Apr 2006 | US |
Child | 12838469 | US |