Patent Application
20250207407
None.
Example embodiments relate to systems and methods for mounting a panel onto a wall, for example, to mounting drywall onto uneven or bowed frame components of a wall.
Drywall is usually a large, rigid sheet of finished material used to cover interior walls of homes, commercial, and other building structures. Hanging drywall generally involves positioning the panel of drywall flush against the framing components of the wall, including studs, ensuring that the edges are perpendicular with the framing components. The installer then fastens the panel by driving drywall screws through the drywall into the framing component behind the drywall. To do that, installers usually visually estimate where along the panel to drive the drywall screws through into the studs. Since drywall must be secured directly to the studs, if the studs are not plumb or vertical and/or are bowed, then the drywall typically takes the non-vertical/bowed form of the studs. It is difficult to install the drywall such that the panels are plumb and straight when the underlying framing components or wall are not plumb and straight.
It may be advantageous to provide improved and efficient systems and methods for the mounting of panels onto a wall. Additional difficulties with existing systems may be appreciated in view of the Detailed Description, herein below.
Example embodiments relate to a system and method for mounting a panel onto a wall, for example, to mounting drywall onto a wall.
An example embodiment is a panel mount system for securing a panel to a wall, the panel mount system comprising: a backing strip comprising: a mounting plate with a front face for contact with the panel, an opposed rear face, and a plate opening extending therebetween; and a rim extension extending from the front face around the plate opening for extension through the panel, the rim extension comprising an internal coupling component, and further dimensioned to receive a body of a screw therethrough; and the screw comprising: a head; and the body extending from the head for securement to the wall, the body having an external coupling component configured to releasably couple with the internal coupling component of the rim extension when the body of the screw extends through the rim extension.
In some examples of the panel mount system, the external coupling component of the body of the screw and the internal coupling component of the rim extension collectively form a snap-fit mechanism.
In some examples of the panel mount system, the external coupling component of the body of the screw is a groove, and the internal coupling component of the rim extension is a ridge dimensioned to fit within the groove of the screw.
In some examples of the panel mount system, the external coupling component of the body of the screw is positioned proximate the head of the screw.
In some examples of the panel mount system, a height of the rim extension corresponds with a width of the panel.
In some examples of the panel mount system, the head of the screw further comprises an outwardly extending washer, the washer having a diameter that is larger than a diameter of the rim extension; wherein in use, the panel is positioned between the washer and the front face of the backing strip.
In some examples of the panel mount system, the body of the screw further comprises a flange extending from the body, the flange positioned to hold the washer in positioned relative to the head of the screw and dimensioned to fit through the rim extension.
In some examples of the panel mount system, the flange is positioned to align with the mounting plate in use.
In some examples of the panel mount system, the backing strip further comprises: one or more spacer plates extending from the mounting plate, a frangible section separating the mounting plate and the one or more spacer plates from each other.
In some examples of the panel mount system, the frangible section comprises one or more apertures.
In some examples of the panel mount system, the backing strip is plastic.
In some examples of the panel mount system, the panel mount system further comprises another mounting plate with another plate opening and another rim extension extending from around the other plate opening for extension through the panel.
In some examples of the panel mount system, the panel mount system further comprises an insert nut having: external threads to secure the insert nut to a frame component of the wall; and internal threads to securely receive the body of the screw therethrough.
In some examples of the panel mount system, the panel mount system further comprises the panel having a panel opening dimensioned to tightly receive the rim extension therethrough.
An example embodiment is a method for mounting a panel to a wall, the method comprising: coupling a backing strip to a back side of the panel, the coupling comprising fitting a rim extension surrounding a plate opening in the backing strip through a panel opening in the panel, the rim extension having an internal coupling component; inserting a body of a screw, from an opposed front side of the panel, through the rim extension, plate opening, and the panel opening, the body of the screw having an external coupling component; releasably coupling the external coupling component of the screw with the internal coupling component of the rim extension to hold the panel therebetween; and securing the body of the screw to the wall, thereby securing the panel to the wall.
In some examples of the method, the releasably coupling comprises snap-fitting the external coupling component of the screw with the internal coupling component of the rim extension.
In some examples of the method, the screw further comprises a head with a washer extending therefrom, the washer having a greater diameter than a diameter of the rim extension, and wherein the inserting of the body of the screw through the rim extension comprises inserting the body of the screw until the washer comes into contact with the rim extension.
In some examples of the method, the securing of the body of the screw into the wall comprises rotating the screw to thread the body of the screw into the wall.
In some examples of the method, the securing of the body of the screw into the wall further comprises securing an insert nut into the wall, and rotating the screw to thread the body of the screw into the insert nut in the wall.
In some examples of the method, the method further comprises cutting the panel opening in the panel.
In some examples of the method, the backing strip comprises a mounting plate from which the rim extension extends, the backing strip further comprising one or more spacer plates extending from the mounting plate, the method further comprising: adjusting a length of the backing strip by removing at least one of the one or more spacer plates from the mounting plate.
In some examples of the method, the backing strip further comprises a frangible section separating the mounting plate and the one or more spacer plates from each other, wherein removing the at least one of the one or more spacer plates from the mounting plate comprises manually breaking off the at least one of the one or more spacer plates from the mounting plate at the corresponding frangible section.
In some examples of the method, the method further comprises coupling another rim extension surrounding another plate opening in the backing strip through another panel opening in the panel; inserting another screw, from the front side of the panel, through the other rim extension, the other plate opening, and the other panel opening, the body of the other screw having another external coupling component; releasably coupling the other screw with the other rim extension; and securing the other screw to the wall.
An example embodiment is a kit for assembling a panel mount system for securing a panel to a wall, the kit comprising: a backing strip comprising: a mounting plate with a front face for contact with the panel, an opposed rear face, and a plate opening extending therebetween; and a rim extension extending from the front face around the plate opening for extension through the panel, the rim extension comprising an internal coupling component, and further dimensioned to receive a body of a screw therethrough; and the screw comprising: a head; and the body extending from the head for securement to the wall, the body having an external coupling component configured to releasably couple with the internal coupling component of the rim extension when the body of the screw extends through the rim extension.
According to an example embodiment is a use of any of the above panel mount systems by performing any of the above methods.
Reference will now be made, by way of example, to the accompanying drawings which show example embodiments, and in which:
Reference will be made below in detail to exemplary embodiments which are illustrated in the accompanying drawings. Wherever possible, the same reference numerals used throughout the drawings refer to the same or like parts.
Turning first to
The backing strip 12 comprises a mounting plate 18a with a front face 20 for contact with the front or back side 110, 112 of the panel 100, an opposed rear face 22, and a plate opening 24 extending between the front face 20 and the rear face 22. In the depicted embodiment, the plate opening 24 is circular. However, in other examples, the plate opening 24 may have a different shape, such as oval or rectangular. The backing strip 12 further has a rim extension 26 extending from the front face 20 around the plate opening 24. Since the plate opening 24 in the depicted embodiment is circular, the rim extension 26 is, correspondingly, generally cylindrical. The rim extension 26 is configured to extend through the panel 100. To that end, the panel 100 may have a panel opening 108 dimensioned to receive the rim extension 26 therethrough, and the height of the rim extension 26 may correspond with the width of the panel 100, such that the rim extension 26 does not extend past the panel 100 in use. As will be further described below, the rim extension 26 is dimensioned to receive a body 36 of the screw 14 therethrough and comprises an internal coupling component 28.
The backing strip 12 may further have one or more additional spacer plates 18b secured to or extending from the mounting plate 18a. As best seen in
In examples where the backing strip 12 comprises multiple plates 18a, 18b, the backing strip 12 may also have a frangible section 30 separating each plate 18a, 18b from one another. The frangible section 30 may be frangible based on its material and/or its shape. For example, the frangible section 30 made of frangible material, such as plastic or composite metal materials. To that end, the plate 18a, 18b and the frangible sections 30 may be made of the same material, such as plastic, or they made be formed from different materials. The frangible section 30 may additionally or alternatively be thinner than the adjacent plates 18a, 18b, scored, perforated, and/or comprise one or more apertures 32 extending therethrough.
In the embodiment depicted in
Returning to
The body 36 of the screw 14 comprises a threaded portion 40 and a coupling portion 42. The threaded portion 40 is generally positioned opposite the head 34 of the screw 14, and is threaded for securement to the stud 106. The coupling portion 42 may be positioned between the washer 38 and the threaded portion 40, and in some examples, may be positioned proximate or adjacent to the head 34 of the screw 14. Notably, the coupling portion 42 comprises an external coupling component 44 configured to releasably couple with the internal coupling component 28 of the rim extension 26 when the body 36 of the screw 14 extends through the rim extension 26.
The external coupling component 44 of the body 36 of the screw 14 and the internal coupling component 28 of the rim extension 26 may relasably couple together via one of a variety of means, including a friction fit, magnetic attraction, or they may collectively form a snap-fit mechanism. In the embodiment depicted in
The threaded portion 40, the coupling portion 42, the head 34, and the washer 38 may be formed or secured together as a unitary piece. In some examples, the washer 38 may be rotatably secured around the head 34 of the screw 14. In such cases, the body 36 of the screw 14 may further include a flange 50 extending from the body 36, the flange 50 being positioned along the body 36 to operatively hold the washer 38 in place around the head 34 of the screw 14. In the example depicted in
While the threaded portion 40 of the screw 14 may be drilled directly into the frame components 102, including studs 106, the panel mount system 10 may optionally include the insert nut 16. As best seen in in
When coupled together, as shown in
At step 1202, the method 1200 may include cutting a panel opening 108 in a panel 100. The panel opening 108 may be dimensioned to fit around (i.e. be larger than) the rim extension 26 of the backing strip 12, and is preferably dimensioned to correspond and snugly fit around the rim extension 26 of the backing strip 12. In the embodiment shown in
If the backing strip 12 is made up of multiple plates, including multiple mounting plates 18 and/or multiple spacer plates 18b, at step 1204, the backing strip 12 may be reduced to a desired length, such as to correspond to a dimension of the panel 100. To that end, the backing strip 12 may be cut to the desired length with a cutting tool. Alternatively, if the plates of the backing strip 12 has frangible sections 30 (in an example, the frangible sections 30 may be perforated or scored), at step 1206, the backing strip 12 may be reduced in length by breaking the backing strip 12 along one of the frangible sections (see
At step 1208, the method 1200 includes coupling the backing strip 12 to one side, either the front or back side 110, 112, of the panel 100. In examples, at step 1210, the coupling may include fitting the rim extension 26 into the panel opening 108. If the backing strip 12 comprises more than one mounting plate 18, the coupling may include fitting each rim extension 26 into its corresponding panel opening 108 (see
At step 1212, the body 36 of the screw 14 may be inserted through the rim extension 26 from the side opposite from where the backing strip 12 is coupled to the panel 100, such that a (preferably significant) portion of the body 36 of the screw 14 extends past the backing strip 12. If the screw 14 has a washer 38, at step 1214, the body 36 of the screw 14 may be inserted through the rim extension 26 until the washer 38 comes into contact with the rim extension 26 and/or the panel 100. In the embodiment depicted in
At step 1216, as or after the body 36 of the screw 14 is inserted through the rim extension 26, the external coupling component 44 of the screw 14 is coupled with the internal coupling component 28 of the rim extension 26. Depending on the structure of the external coupling component 44 and the internal coupling component 28, the external coupling component 44 and the internal coupling component 28 may be pressed together in a friction fit, via magnetic attraction, or they may be snap-fitted together (at step 1218). The coupling between the external coupling component 44 and the internal coupling component 28 may be permanent or releasable.
If another panel mount system 10 is to be coupled to the panel 100, the method 1200 may return to step 1202 or 1204 as necessary.
At step 1220, the panel 100 may be secured to the framing component 102, such as the stud 106, by securing the body 36 of the screw 14 to the framing component 102. If the body 36 of the screw 14 is relatively smooth, the body 36 (that extends past the backing strip 12) may be hammered into the framing component 102. If the screw 14 has a threaded portion 40, the threaded portion 40 (that extends past the backing strip 12) may be rotated/driven into the wall. In examples, the body 36 of the screw 14 may be secured directly into one of the frame components of the wall (such as the top or bottom rail 104 or a stud 106).
In other examples, the method 1200 may include, at step 1222, securing an insert nut 16 into the top or bottom rail 104 or the stud 106 (see
If multiple panel mount systems 10 were coupled to the panel 100, at step 1220, the panel 100 may be secured to the framing component 102 by securing each of the bodies 36 of the screws 14 to the framing component 102 using one of the manners described above. As described above, each panel mount systems 10 allows the portion of the panel 100 immediately adjacent to it to be moved towards or away from the stud 106 by turning its screw 14 independently of the other panel mount systems 10. In other words, at step 1226, each panel mount system 10 may be used to independently adjust the distance of its portion of the panel 100 relative to the stud 106 by turning each screw 14 clockwise or counter clockwise. In that manner, the overall orientation of the panel 100 can be adjusted relative to the studs 106 to be plumb, straight and/or level (with the floor, for example), even when the underlying framing component 102 or stud 106 is not plumb, straight and/or level. Thus, the panel 100 can be levelled without using drywall compound or other conventional leveling methods.
While some of the above examples have been described as occurring in a particular order, it will be appreciated to persons skilled in the art that some of the steps or processes may be performed in a different order provided that the result of the changed order of any given step will not prevent or impair the occurrence of subsequent steps. Furthermore, some of the steps described above may be removed or combined in other embodiments, and some of the steps described above may be separated into a number of sub-steps in other embodiments. Even further, some or all of the steps may be repeated, as necessary. Elements described as methods or steps similarly apply to systems or subcomponents, and vice-versa.
Variations may be made to some example embodiments, which may include combinations and sub-combinations of any of the above. The various embodiments presented above are merely examples and are in no way meant to limit the scope of the examples. Variations of the innovations described herein will be apparent to persons of ordinary skill in the art having the benefit of the examples, such variations being within the intended scope of the example embodiments. In particular, features from one or more of the above-described embodiments may be selected to create alternative embodiments comprised of a sub-combination of features which may not be explicitly described above. In addition, features from one or more of the above-described embodiments may be selected and combined to create alternative embodiments comprised of a combination of features which may not be explicitly described above. Features suitable for such combinations and sub-combinations would be readily apparent to persons skilled in the art upon review of the example embodiments as a whole. The subject matter described herein intends to cover and embrace all suitable changes in technology.
Certain adaptations and modifications of the described embodiments can be made. Therefore, the above discussed embodiments are considered to be illustrative and not restrictive.
