U.S. patent application number 11/706839 was filed with the patent office on 2007-10-11 for wallboard appurtenance attachment.
Invention is credited to Kerry Baran, Herbert Woiczyk.
Application Number | 20070235622 11/706839 |
Document ID | / |
Family ID | 38372147 |
Filed Date | 2007-10-11 |
United States Patent
Application |
20070235622 |
Kind Code |
A1 |
Baran; Kerry ; et
al. |
October 11, 2007 |
Wallboard appurtenance attachment
Abstract
The present invention serves to anchor appurtenances to
wallboards without requiring a hollow void or cavity behind the
wallboard and providing a secure stable attachment. In preferred
embodiments, the wallboard anchor of the present invention has an
arcuate shank or prong, having a distal point, that is inserted
into the wallboard on an upward curved path, a wall engaging
portion proximate the arcuate prong contacts and engages the outer
surface of the wall. Preferably, the wall-engaging portion presents
a vertical flat surface and the arcuate prong extends directly from
the flat surface of the wall-engaging portion, initially
perpendicularly from the, and then sweeps upwardly with a radius of
curvature. The radius of curvature is preferably about equal to or
less than the thickness of the wallboard to which the appurtenance
is attached. The appurtenance with the wallboard anchor attached is
attached by inserting the prongs into the wallboard horizontally
and rotating the appurtenance downwardly toward the wall to seat
the appurtenance against the wall. Removal is by rotating the lower
portion upwardly away from the wall.
Inventors: |
Baran; Kerry; (Kelowna,
CA) ; Woiczyk; Herbert; (Summerland, CA) |
Correspondence
Address: |
PATTERSON, THUENTE, SKAAR & CHRISTENSEN, P.A.
4800 IDS CENTER
80 SOUTH 8TH STREET
MINNEAPOLIS
MN
55402-2100
US
|
Family ID: |
38372147 |
Appl. No.: |
11/706839 |
Filed: |
February 14, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60772983 |
Feb 14, 2006 |
|
|
|
Current U.S.
Class: |
248/546 |
Current CPC
Class: |
A47H 1/102 20130101;
F16B 45/00 20130101; A47F 5/0823 20130101; A47G 1/20 20130101; F16B
15/00 20130101; F16B 35/00 20130101; A47B 96/027 20130101 |
Class at
Publication: |
248/546 |
International
Class: |
A47F 5/08 20060101
A47F005/08 |
Claims
1. A method of securing an appurtenance to a wall, the wall having
a wallboard, the wallboard having a thickness and comprising a
gypsum core with sheathing material on an interior surface and an
outer exposed surface, the appurtenance having an upright
attachment position, a front side for facing away from the wall and
a back side for facing the wall, the appurtenance having a wall
confronting region on said back side, said wall confronting region
having an upper most top edge on the wall confronting region, the
method comprising the steps of: providing a wall anchor with an
arcuate prong and a point at the end of said prong, the arcuate
shank having a radius of curvature; fixing the wall anchor to the
wall confronting region of the appurtenance below the uppermost top
edge by a distance of about or less than 120% of radius of
curvature of the arcuate shank such that when the appurtenance is
upright, the arcuate extends rearwardly from the appurtenance and
arcs upwardly with the point oriented upwardly; positioning the
appurtenance so that its back side is facing downward and the
arcuate shank extends downward and arcs toward the wall with the
point confronting the wall, puncturing the surface of the wallboard
with the point of the arcuate shank; inserting the arcuate shank
into the wallboard upon an arcuate path corresponding with the
shape of the arcuate shank by rotating the appurtenance downward
approximately about the uppermost top edge of the wall confronting
portion of the appurtenance.
2. The method of claim 1, further comprising the step of fixing an
addition prong to wall engaging portion, the additional prong
positioned below the arcuate prong and oriented to pierce the wall
when the appurtenance is rotated downward.
3. The method of claim 2 further comprising the step of using the
engagement of the wall with the uppermost top edge portion of the
appurtenance to guide the downward rotation of the
appurtenance.
4. An appurtenance for attaching to a wall, the appurtenance having
an upright position with a vertical wall confronting region, an
arcuate prong fixed to the appurtenance at the wall confronting
region, said prong having a curved shank with a distal point,
whereby when the appurtenance is upright the shank extends
therefrom laterally and gradually curving upward such that the
point is directed upwardly, the shank extending from the
appurtenance, the prong is no longer than 1.25 inches measured
along the lower profile of the prong.
5. The appurtenance of claim 4 wherein the appurtenance weighs at
least one pound.
6. The appurtenance of claim 4 wherein the angle from horizontal
between a point where the arcuate prong is fixed to the
appurtenance to the distal point of the prong is at least 30
degrees.
7. An appurtenance for attaching to a wall, the appurtenance having
a wall confronting region, an arcuate hook fixed to the
appurtenance at the wall confronting region, said hook having a
curved shank with a distal point, whereby when the appurtenance is
upright the shank extends therefrom laterally and gradually curving
upward such that the point is directed upwardly, the shank
extending from the appurtenance at a point spaced from the
uppermost top edge about equal to or less that the distance from
the point to the appurtenance, the appurtenance weighing at least
one pound.
8. A method of attaching a wall anchor to a vertical surface of a
gypsum based wallboard, the method comprising the steps of:
inserting an shank having an arcuate shape and a distal point into
the exterior surface of the gypsum based wallboard at an entry
point, guiding the shank inwardly and upwardly along an arcuate
path within the gypsum based wallboard corresponding to the shape
of the shank whereby the distal point is directed upwardly,
engaging a flange portion connected to the shank with the exterior
vertical surface of the gypsum based wallboard, proximate the entry
point whereby the distal point is no more than 1 inch above a point
where the flange portion connects to the shank.
9. The method of claim 8 further comprising the step of attaching
an appurtenance to the flange portion.
10. The method of claim 8 wherein the wall anchor does not have a
hook opposite the arcuate shaped shank.
11. The method of claim 6 further comprising the step of
positioning the distal point of the shank at a angular position of
greater than 30 degrees measured from the horizontal.
12. A method of manufacturing an appurtenance with wall attachment
means, the appurtenance having a weight of at least five pounds an
upright position and a wall engaging region having an uppermost
edge; providing an arcuate shank and a pointed tip, the arcuate
shank having a tip pointing upwardly positioning and fixing the
arcuate shank no more than 1.25 inches below the uppermost
edge.
13. A method of manufacturing an appurtenance with wall attachment
means, the appurtenance having a weight of at least five pounds an
upright position and a wall engaging region having an uppermost
edge; providing an arcuate shank and a pointed tip, the arcuate
shank having a tip pointing upwardly, the arcuate shank having a
radius of curvature of less than 1 inch.
14. A wall attachable appurtenance, the appurtenance having a front
side, a back side, an upright attachment position, a wall
confronting region with an uppermost top edge on the wall
confronting region, the appurtenance having an arcuate hook fixed
to the appurtenance at the confronting region, said hook having a
curved shank with a distal point, the shank extending from the
appurtenance laterally and gradually curving such that the point is
directed upwardly, the shank extending from the appurtenance at a
point spaced from the uppermost top edge about equal to or less
that the distance from the point to the appurtenance, whereby the
appurtenance can be rotated about 90 degree from the upright
position whereby the back side is facing downward and such that the
point of the hook can be initially inserted into the wall and then
completely inserted into the wall by rotating the appurtenance
about the uppermost edge downward
15. A method of securing an appurtenance to a wall with a
wallboard, the wallboard having a thickness and comprising a gypsum
core with sheathing material on an interior surface and an outer
exposed surface, the appurtenance having an upright attachment
position, a wall confronting region with an upper most top edge on
the wall confronting region, the appurtenance having an arcuate
hook fixed to the appurtenance at the confronting region, said hook
having a curved shank with a distal point, whereby when the
appurtenance is upright the shank extends therefrom laterally and
gradually curving upward such that the point is directed upwardly,
the shank extending from the appurtenance at a point spaced from
the uppermost top edge about equal to or less that the distance
from the point to the appurtenance.
Description
[0001] This application claims priority to Provisional Application
Ser. No. 60/772,983 filed Feb. 14, 2006, said application being
incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] This invention relates to attachment of appurtenances to
wallboard. More particularly it relates to methods of such
attachment and apparatus for such attachment.
BACKGROUND OF THE INVENTION
[0003] 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 has for the most
part replaced plaster walls previously common in residential and
commercial construction. Referring to FIG. 1, wallboard 110 is
comprised of a pair of sheathings 111, 112 or liners on both sides
of a gypsum based core 113. The liner material can be paper,
polymers, or other sheet materials. Gypsum wallboard, in the United
States, is available in thicknesses of 4 inch (6.35 mm) 3/8, 1/2,
5/8, 3/4, and 1 inch (25 mm) with 1/2 inch being the most commonly
used.
[0004] 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 120, are not effective in drywall except for holding very
modest weights due to the concentration of force at cross hatched
and angled dashed region 140 of FIG. 1. Weight W1 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 M1 caused by W1
about the generalized pivot region P1 of the nail generally
provides a dislodgement force component F10 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.
[0005] 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 with usually 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. 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.
[0006] Use of curved anchors with no moving parts for attachment to
wallboard have typically either required first creating a
horizontal hole through the wallboard in a separate operation or
utilize a pointed end that punctures the wallboard and extends
essentially horizontally therethrough. Typically a pointed rigid
wire prong pierces the wallboard into the cavity or hollow behind
the wallboard, having the wire curve upwardly and around to engage
in inner surface of the wallboard thereby distributing the shear
force to the liner on the second (hidden) surface of the
wallboard.
[0007] U.S. Pat. No. 6,478,273 issued to McKeiernan, Jr. et al. on
Nov. 12, 2002 titled "Wall Tack", teaches an improved 3 prong wall
tack for upholstered wall surface or the like. The tack
incorporates two prongs with curves formed and pointed on the ends
pointing orthogonally relative to the major surface of the tack
body. The 90 degree bend is in a limited area, approximately less
than 50% of the expanded length of the prong, medially between the
point and the tack body. This is not identified or suggested for
use on gypsum wallboard and the "tight" 90 degree turn would not be
conducive to solid attachment in the core due to the disruption of
the core during. In the case of wallboard type of installation, the
3 prong wall tack would expectedly require a hollow or void behind
the wallboard to accommodate the bent prongs.
[0008] U.S. Pat. No. 6,431,510 issued to Lydecker et al. on Aug.
13, 2002 titled "Hanging Device and Method of Making Same", teaches
of a hanging device using a similar round wire bent at 90 degrees
with a vertically pointed tip when installed. This has a similar
pressure gradient problem as in the previous patent, and would only
work on wallboard with a hollow or void behind it.
[0009] U.S. Pat. No. 6,126,126 issued to McKeirnan Jr. on Oct. 3,
2000 titled "Tack with Three Prongs", teaches a three prong tack
having a rigid flat body with three round wire prongs extending
from one surface, with two of the prongs angled at less than 90
degrees from the body of the tack, while the third prong is normal
to the body of the tack U.S. Pat. No. 4,619,430 issued to Hogg on
Oct. 28, 1986 titled "Picture Frame Hanger", teaches a back plate
with hook and wire attached to a hollow wall using a pointed wire
in two preferred embodiments, one arched, the other straight bent.
The arched embodiment results in the round wire point
re-penetrating the surface opposite back plate. The second
embodiment has a bent wire with the bend angle less than 90 degrees
so that the wire tangentially engages interfaces with the opposite
surface of the hollow wall. U.S. Pat. No. 4,422,608 issued to Hogg
on Dec. 27, 1983 titled "Panel Hanger", teaches a vertical panel
hanger with a round wire shank with needle point penetrator
positioned to engage the rear surface of a panel to prevent removal
of the hanger, with the shank attacked to a disc with its rear
surface covered in pressure sensitive adhesive to prevent lateral
movement. This has a similar pressure gradient problem as in
previously noted patents, and would only work on wallboard with a
hollow or void behind it.
[0010] U.S. Pat. No. 3,219,302 issued to Smith on Nov. 23, 1965
title "Wall Hanger", teaches a formed wire hanger made of round
wired with a sheared end to make a penetrating point. The hanger
can be inserted through drywall with a hollow cavity behind the
drywall, with the profile of the wire bringing the heel of the wire
in tangential contact with the inside surface of the hollow wall
panel. This has a similar pressure gradient problem as in
previously noted patents, and would only work on wallboard with a
hollow or void behind it.
[0011] U.S. Pat. No. 2,789,783 issued to Jones on Jun. 1, 1953
titled "Hanger", teaches a formed wire hanger made of round wire
with a swaged pointed end, with the flat surface of the swag
aligned orthogonally to the hollow plaster wall panel surface, and
contacting the wall panel surface at the swaged end. This has a
similar pressure gradient problem as in previously noted patents,
and would only work on wallboard with a hollow or void behind
it.
[0012] In each case of prior art cited the anchoring device
requires a hollow section within the wall for the formed wire
apparatus to reside. The anchors cited are made of round wire and
either pointedly or tangentially interface with the hidden side of
the wallboard panel, both of which have a high stress concentration
against the panel when the anchor is loaded. Such an exemplary
prior art design is illustrated in FIG. 1b. These hangers involve
some intricate manipulation for attachment and removal and cannot
readily be attached to separate appurtenances, other than a simple
hood, before use.
[0013] Other wall anchors that utilize curved insertion members
require or teach insertion such that the pointed end of insertion
prongs extends downwardly in the wall. See U.S. Pat. Nos.
3,298,651; 4,300,745; and 5,029,788. Referring to FIG. 1c, a
representative anchor is illustrated with an arcuate prong 120, a
surface engagement portion 122. Indeed, where objects are suspended
from these hangers any distance d1 from the wallboard surface, a
force moment M2 is created in the rotational direction away from
the wall and downward. This translates to the force represented by
arrow F12 that provides a bias or urging outwardly of the
downwardly extending arcuate prong. This force effectively operates
about the lowest edge P2 of the surface engagement portion which
functions as a pivot. The smaller the distance between the arcuate
prong and the pivot P2, the greater the force F12 urging the anchor
out of the wall. The moment M2 effectively operates to dislodge the
anchor. To the extent that the prior art anchor loosens increasing
the distance d1, the dislodging moment M2 increases which
correspondingly increases the dislodging force F12 which increases
the probability of a failure of the attachment. Such anchors are
not suitable for appurtenances that have their center of gravity
displaced from the wall any significant distance that enhances the
dislodging moment.
SUMMARY
[0014] The present invention serves to anchor appurtenances to
finished wallboards without requiring a hollow void or cavity
behind the wallboard and providing a secure stable attachment. In
preferred embodiments, the wallboard anchor of the present
invention has an arcuate shank or prong, having a distal point,
that is inserted into the wallboard on an upward curved path, a
wall engaging portion proximate the arcuate prong contacts and
engages the outer surface of the wall. Preferrably, the
wall-engaging portion presents a vertical flat surface and the
arcuate prong extends directly from the flat surface of the
wall-engaging portion, initially perpendicularly, and then sweeps
upwardly with a radius of curvature. The radius of curvature is
preferrably about equal to or less than the thickness of the
wallboard to which the appurtenance is attached. Preferrably, the
wall engaging portion has an upper edge that may operate as a pivot
for installation into the wall. The upper edge portion is
positioned approximately a distance equal to or less than 120% of
the radius of curvature. With the curved prong and wall-engaging
portion attached or part of the appurtenance, the appurtenance is
rotated about 90 degrees so that the point of the prong is
extending horizontally toward the wall with the point of the
arcuate prong at a desired entry point on the wall. The point of
the prong is inserted into the wall such and is rotatably lowered
about a pivot point defined as the upper edge engaged with the
wall. The appurtenance is lowered 90 degrees to the vertical
upright position and where the wall engaging portion is flush with
the wall.
[0015] The arcuate shank and is connectable to or is attached to an
appurtenance such as household or office items, not limited to
shelving, picture frames, posters, racks, tooth brushes, toilet
paper, decorative items, window treatments, cabinets and operative
devices, such as clocks, speakers, and other electrical items. The
appurtenance can also be a hook for receiving items such as a
picture hanging wire. In preferred embodiments, the upper edge of
the wall-engaging portion is a straight.
[0016] A feature and advantage of the invention is that the
invention defies the reasonable expectation that an anchor
comprising an upwardly extending arcuate prong inserted in a
wallboard would provide very significant weight carrying
capability.
[0017] A feature and advantage of preferred embodiments is that the
anchor mechanism may be readily incorporated as part of household,
office, garage, or industrial appurtenances that attach to walls. A
further feature and advantage of preferred embodiments is that the
anchor mechanism may be readily attached to appurtenances that
attach to walls such that the appurtenance is readily attached by
inserting the attached prong into the wall and lowering the
appurtenance while guiding in the arcuate prong.
[0018] A feature and advantage of preferred embodiments of the
invention is that the weight of the attached appurtenance
effectively provides a moment that operates in a rotational
direction to secure rather than loosen and release the arcuate
shank. The arcuate shank minimizes shear stress concentration in or
on the wallboard panel. Thus, a feature and advantage of preferred
embodiments is that gravity effectively secures the anchor or
anchor and appurtenance in place.
[0019] The efficacy and weight bearing capability of the anchor
attached with the upwardly extending arcuate path is
counterintuitive, particularly when the anchor is embedded in
gypsum wallboard.
[0020] A feature and advantage of preferred embodiments is that
such are readily and easily installed in wallboard, and in
particular, gypsum based wallboard, and does not require any tools
for installation.
[0021] A feature and advantage of the invention is that optimal
installation is provided using an easy leveraged mounting motion,
rotationally lowering from horizontal the anchor base or attached
appurtenance.
[0022] A feature and advantage of preferred embodiments is removing
the anchor and any attached appurtenance is accomplished simply by
pulling away from the wall and the lower portion of the wall
engaging portion to just past horizontal. The upper edge naturally
pivots upon the wall surface and the anchor is thus dislodged with
no further manipulation. If a shelf or other sizeable appurtenance
is associated with the anchor, the appurtanence is simply rotated
upwardly to horizontal and the anchor is dislodged.
[0023] A feature and advantage of preferred embodiments is that
there is minimal disruption of the core of wallboard when inserted
therein. The smooth arcuate shape that encompasses a majority of
the extended length of the arcuate prong follows a path defined by
the arcuate shape and does not crush the core much outside the
actual path.
[0024] In a preferred embodiment, the appurtenance includes the
arcuate prong wall-engaging portion integral with or fixedly
attached thereto.
[0025] In a preferred embodiment, a curved arcuate prong has a
threaded extended straight shaft that allows insertion into wood or
wood products for manufacturing an appurtenance with the anchor
integral therewith. Preferrably, the appurtenance has a flat
surface allowing the threaded straight shaft to be driven therein
perpendicular to the flat surface. The flat surface of the
appurtenance then becomes the wall-engaging portion. Preferrably,
the wall engaging surface has an upper edge portion for the
pivoting installation of the appurtenance. Preferrably the upper
edge portion is positioned at a distance about equal to the radius
of curvature of the arcuate prong.
[0026] In preferred embodiments the anchor includes a second
subordinate prong extending from wall-engaging surface. This prong
is preferrably either straight or has a radius of curvature about
equal to the distance from the prong to the upper edge portion.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1a is a cross-sectional depiction of a known prior art
utilization of a nail in gypsum wallboard for supporting a
weight.
[0028] FIG. 1b is a cross-sectional depiction of a known prior art
wallboard hanger.
[0029] FIG. 1c is a cross-sectional depiction of a known prior art
wallboard anchor utilizing an arcuate hook with the anchor inserted
into gypsum wallboard.
[0030] FIG. 2a is a cross-sectional view of an embodiment of the
invention.
[0031] FIG. 2b is a perspective view of the wall anchor and
appurtenance of FIG. 2a.
[0032] FIG. 3a-d illustrate attachment of an embodiment of the
invention to a wallboard.
[0033] FIG. 4 is a side view of a wall anchor with a flat on the
upper surface of the prong.
[0034] FIG. 5 is a top plan view of the wall anchor of FIG. 4.
[0035] FIG. 6 is a front perspective view, an embodiment of the
present invention in the form of a double-sided tack suitable for
use with small picture frames.
[0036] FIG. 7 is a perspective view, an embodiment of the present
invention in the form of a rectangular head tack with double
deformable adhesive applied to the head of the tack.
[0037] FIG. 8a is a perspective view, an embodiment of the present
invention in the form of a screw for anchoring large frame and
shelving items.
[0038] FIG. 8b is a perspective view of a threaded anchor prong and
associated attachment hardware.
[0039] FIG. 9a is a perspective view of an embodiment of the
present invention in the form of a hanger suitable for use as a
picture hanger.
[0040] FIG. 9b is a perspective view of an embodiment of the
present invention in the form of a hanger suitable for use as a
picture hanger.
[0041] FIG. 9c is a perspective view of opposite side of the hanger
of FIG. 9b.
[0042] FIG. 9d is a perspective view of an embodiment of the
present invention in the form of a hanger suitable for use as a
picture hanger.
[0043] FIG. 9e is a perspective view of an embodiment of the
present invention in the form of a punched hanger suitable for use
as a picture hanger.
[0044] FIG. 9d is a side elevational view of the hanger of FIG.
9e.
[0045] FIG. 10 is a perspective view of an embodiment of the
present invention in the form of a bathroom accessory rack mount
such as for towel racks, toilet paper roll holders, toothbrush
rack, etc.
[0046] FIG. 11 is a perspective view of an embodiment of the
present invention in the form of a leaf used in a dual opposing
leaf anchor.
[0047] FIG. 12 is a perspective view of a leaf anchor mounting
plate which orients two leaves in opposition, secured by a single
central screw.
[0048] FIG. 13 is a front perspective view of an embodiment of the
present invention in the form of a dual opposing leaf anchor with
the first of two leaves partially inserted into the mounting plate
and wallboard.
[0049] FIG. 14 is, in front perspective view, an embodiment of the
present invention in the form of a dual opposing leaf anchor with
the first of two leaves substantially inserted and the second of
two leaves partially inserted into the mounting plate and
wallboard.
[0050] FIG. 15 is, in front perspective view, an embodiment of the
present invention in the form of a dual opposing leaf anchor
secured by plate and screw.
[0051] FIG. 16 is, in rear perspective view, an assembled picture
frame using the double-sided tack embodiment of the present
invention.
[0052] FIG. 17 is, in side hidden line view, an assembled picture
frame using the double-sided tack embodiment of the present
invention anchored to wallboard.
[0053] FIG. 18 is, in rear perspective view, an assembled shelf
using anchors of the preferred embodiment of the present
invention.
[0054] FIG. 19 is, in hidden line side perspective view, an
assembled shelf using anchors of the preferred embodiment of the
present invention partially installed onto wallboard.
[0055] FIG. 20 is, in hidden line side view, an assembled shelf
using anchors of the preferred embodiment of the present invention
partially installed onto wallboard.
[0056] FIG. 21 is, in side perspective view, an assembled
toothbrush holder using anchors of the preferred embodiment of the
present invention.
[0057] FIG. 22 is, in hidden line side view, an assembled
toothbrush holder using anchors of the preferred embodiment of the
present invention partially installed onto wallboard.
[0058] FIG. 23 is, in hidden line side view, an assembled towel
rack mount using anchors of the preferred embodiment of the present
invention partially installed onto wallboard.
[0059] FIG. 24 is, in front perspective view, an assembled towel
rack mount using anchors of the preferred embodiment of the present
invention installed onto wall board.
[0060] FIG. 25 is, in front perspective view, an assembled towel
rack holder using anchors of the preferred embodiment of the
present invention installed onto wallboard.
DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION
[0061] Referring to FIGS. 2a and 2b a preferred embodiment of the
present invention of a generalized appurtenance and wallboard
anchor is illustrated. Wallboard 1 has the wallboard anchor 4 and
attached appurtenance 4.5. The wallboard will be part of a wall 1.5
and is illustrated as gypsum wallboard with a core 1.1 and
sheathing 1.2, 1.3; in other embodiments the wallboard may be
comprised of other pierce-able wallboard material. The wallboard
anchor has first anchor means comprising a curved prong or shank 5
is inserted into outside facing surface 2 of the gypsum wallboard.
The curved shank can have a fixed radius of curvature R1, or have
varying radii of curvature at various points, either discretely or
continuous, along the outer profile 5.1 of the prong 5 from the
wall-engaging portion 9 to the piercing distal point or tip 7. The
wall-engaging portion 9 has a wall confronting region 9.1 with a
flat wall facing and engaging surface 9.3 and a uppermost wall
engagement point 9.4 configured as edge or corner is this
embodiment.
[0062] The shank shown in FIGS. 4 and 5 may be flat on the inside
of its curved profile 8 and can be flat on the outside 6 as well.
The flat surface 8 aids in the prevention of pullout due to stress
concentrations on the wallboard panel, particularly when the
wallboard panel is composed of gypsum.
[0063] The point 7 of the anchor may or may not pierce the second
surface 3 of the wallboard 1 as shown in FIGS. 1 and 5. It is
acceptable for the point 7 to just pierce the second surface 3 of
the wallboard in a tangential manner with the anchor surface 8
coincidentally interfacing with the outside of second wallboard
surface 3. It should be noted that for a fixed radius R of
curvature shank 5, the radius of curvature would be approximately
equal to the thickness of the panel T, or slightly less and the
shank would be of circumferential length of one half P1 times the
radius of curvature R1 or less.
[0064] It is not necessary for the shank 5 to pierce the second
wallboard surface 3, nor is it necessary for the shank point 7 to
be coincident with the second surface 3 in order for the anchor to
function effectively.
[0065] The anchor of the present invention will work in situations
where there is no void, cavity, or hollow behind the wallboard 1
second surface 3, wherein the shank point 7 just pierces the second
wallboard surface 3 or does not pierce the second wallboard surface
3. This constitutes a new innovation relative to the prior art,
which requires an open space, void, cavity, or hollow behind the
wallboard 1.
[0066] Referring specifically to FIG. 2a, appurtenance 4.5 has a
weight W3 and a center of gravity c.g. which is spaced from the
interface 4.6 of the wall engaging portion and wall surface 2 by a
distance d2. A moment M3 is created corresponding to the distance
d2 that effects a force F5 on the arcuate prong about the lowermost
point of engagement 9.5 of the wall-engaging portion and the wall
or wallboard surface 2. As can be seen this force is distributed
through the core of the wallboard above the arcuate prong 5. This
is compared to the forces involved in the prior art of simple nails
or downwardly curved prongs that operate to dislodge the
attachment. The core of the wallboard is much more capable of
absorbing this loading than the prior art configurations of FIGS.
1a and 1c. Moreover slight loosening of the prong in the wallboard
does not affect the integrity of the attachment as significantly as
in the prior art.
[0067] Referring to FIGS. 3a, 3b, 3c, and 3d, the methodology of
attachment of an appurtenance with an attached anchor according to
and embodiment of the invention is illustrated. The appurtenance is
this case is a hook or slotted hanging device discussed below with
respect to FIGS. 9b-9d.
[0068] With the curved prong and wall-engaging portion attached or
part of the appurtenance, the appurtenance is rotated about 90
degrees so that the point of the prong is extending horizontally
toward the wall with the point of the arcuate prong at a desired
entry point on the wall; see FIG. 3a. The point of the prong is
inserted into the wall such and is rotatably lowered one quarter of
a rotation about a pivot point defined as the upper edge engaged
with the wall; see FIGS. 3b and 3c. The appurtenance is lowered 90
degrees to the vertical upright position and where the wall
engaging portion is flush with the wall; see FIG. 3d. For removal,
the appurtenant with anchor is simply lifted up by the lower
portion of the wall engaging portion to just past horizontal. The
upper edge naturally pivots upon itself and the anchor is thus
dislodged with no further manipulation.
[0069] Applications requiring the hanging of picture frames or the
like on wallboard may use the anchor of the present invention
taking the form of a Double Headed Tack (DHT) 10 shown in FIG. 6
with the characteristic curved shank 11 with flat surfaces inside
14, and outside 12 terminating in a point 13 distal from head 15.
In addition a straight shank 16 projects from head 15 opposite the
curved shank 11 tapering to a point 17. Typically the anchor 10
would first be inserted into the object to be anchored such as
picture frame 51 as shown in FIGS. 16 and 17, prior to mounting the
object such as frame 51 onto the wallboard 1.
[0070] In applications requiring fastening almost anything of
reasonable mass and adhesable surface, the anchor of the present
invention may take the form of a Tack with an Adhesive Head (T AH)
18 shown in FIG. 7. In this example the tack 18 has a rectangular
head 23 with a layer of adhesive or double sided tape 24 applied to
the head 23 surface opposite shank 19.
[0071] For heavier applications the wallboard anchor of the present
invention may take the form of screw mount shank 25 as shown in
FIG. 8a. In this embodiment the curved shank of the anchor has a
flat 29 and is integral with an opposing screw shank 30 and tip 31
for fastening into a variety of materials to be anchored to
wallboard using curved shank 26 by insertion of the tip 27. FIG. 8b
illustrates another version of such an anchor 30.2 with prong with
a machine screw threads 31 attachable to nuts 31.1. Additional
hardware is illustrated as bracket 31.2 and washer 31.3 which can
be used in different configurations for attachment of various
appurtenances.
[0072] In many applications, such as hanging picture frames or
shelving on wallboard as shown in FIGS. 9a-9d and 16-20, a second
subordinate anchor means configured as a straight prong, an arcuate
prong, a screw, double sided tape, or adhesive tack may be used
below the primary anchor means, the curved prong. The curved shank
anchor keeps the object from pulling away from the wallboard while
the anchor below keeps the object from moving vertically and
potentially dislodging the curved shank anchor. Referring to FIG.
2a, in a most preferred embodiment, a subordinate prong 35 will
have a radius of curvature R2 about equal to the distance between
the subordinate prong and the uppermost point 9.4 of the
wall-engagement portion 9 or straight. In a further embodiment, the
subordinate prong will have a slight curvature downward which will
tend to firmly secure the wall anchor is place.
[0073] Referring again to FIGS. 9a-9f, these wall anchors comprise
a body 33 with a hanger slot 36 defined by a hook 36.4. The curved
shank 34 would be inserted into the wallboard first and as the
hanger 30 rotates downward a second straight shank penetrates the
wallboard until the hanger body 33 comes to rest against the
wallboard. The straight shank 35 prevents the hanger 32 from moving
vertically while the curved shank 34 prevents the hanger 32 from
being pulled away from the wallboard when loaded.
[0074] The invention includes methods of manufacturing wall anchors
and methods of manufacturing appurtenances with integral or
attached wall anchors. FIGS. 9a-9f illustrate embodiments that
would be manufactured in distinct ways with the commonality of
providing a flat wall engagement portion with a prong extending
initially perpendicularly therefrom and curving upwardly following
a simple or complex radius of curvature. Typically the prong will
be metal, such as steel, although certain other materials such as
high strength polymers may be suitable, for example
polyetheretherketone (PEEK). The embodiment of FIG. 9a can have the
metal prongs insert molded into the body formed of a polymer. The
body could also be diecast. The prongs would conveniently be formed
from a single piece of bent steel wire.
[0075] The embodiments as illustrated in FIGS. 9b, 9c, and 9d can
be formed by folding or stamping a piece of sheet metal, extending
the prongs through holes in the body and securing the prongs by
suitable crimping of the body or welding. The embodiment of FIGS.
9e and 9f resemble a tack strip used in furniture manufacture. The
prongs and openings are formed by stamping to produce a strip that
has easy bending break points 33.5 for providing discrete wall
anchors with hanging hooks 36.4.
[0076] The invention also includes providing an assortment of
differently sized wall anchors with or without appurtances, for
installation in specific sizes of wallboard. The lengths and
curvatures of the arcuate prongs will vary to allow optimum
selection of a hanger for a specific thickness of wallboard, for
example gypsum wallboard. Moreover, different bodies can be
provided with different attachment capabilities, or different
appurtenances attached thereto, for example, slots or catches for
hanging, and a threaded stud for attachment. Moreover an attachment
tool can be provided to aid installation of specialty prongs.
[0077] The invention also includes selection of a suitably sized
wall anchor from a plurality of sizes, or types, for a specific
thickness of wallboard. For example for 1/2 inch wallboard a prong
with a radius of curvature of about 1/2 inch or less and an upper
most pivot point on the wall engagement portion of about 1/2 inch
or less. The suitable size, meaning the radius of curvature, or
alternatively, the distance the prong extends horizontally (that
is, in the z direction) is preferably the size that corresponds to
the thickness of the wallboard or less.
[0078] Referring to FIG. 3d, another aspect of the invention is
providing a wall anchor that, when in the upright position, has the
tip of the arcuate prong extending a distance 1/4 no more than
preferably 1/2 inch above the uppermost point of the wall
engagement portion 9. A more preferable embodiment is where the
uppermost point extends no more than 1/4 inch above the uppermost
point of the wall engagement portion 9. A most preferable
embodiment is where the uppermost point extends no more than 1/8
inch above the uppermost point of the wall engagement portion
9.
[0079] Referring to FIG. 3d, another aspect of the invention is a
wall anchor with an arcuate prong that extends into one surface of
wallboard, not out the opposite surface, and that has an arcuate
portion that is curved upwardly with a piecing tip that is at an
angle A1 from horizontal set at the entry point of the prong of at
least 20 degrees. In a more preferred embodiment the angle A1 is at
least 30 degrees. In an even more preferred embodiment the angle A1
is at least 40 degrees.
[0080] An embodiment of the present invention for hanging towel
racks, curtain rods, toilet paper rolls, and the like from
wallboard is shown as Towel Rack Mount 37 in FIG. 10. In this case
the standard towel rack mount plate 38 has two anchors 39 added to
it.
[0081] For anchoring applications on both horizontal and vertical
surfaces the dual anchor leaf embodiment of the present inventions
shown in FIGS. 11 through 15 would provide securing means. This
embodiment uses two anchor leaves 40 placed in opposing outward
orientation through dual anchor leaf mounting plate 47 slots 48 and
into wallboard 1 through first surface 2, and secured in place by
fastener 50 acting on anchor leaf head 45 through anchor leaf hole
46 and dual anchor leaf mounting plate fastener hole 49. In this
embodiment the present invention also compresses the wallboard
slightly between the anchor leaf 40, inner surface 44, and the
wallboard-mating surface of the Dual Anchor Leaf Mounting Plate 47.
This anchor can be used for anchoring objects to ceilings or walls
as the two opposing anchor leaves 40 retain the anchor in place on
the wallboard irrespective of gravity and its direction relative to
the anchor.
[0082] Referring to FIGS. 18, 19, and 20 a appurtenant configured
as a shelf component 53 has a pair of first anchor means configured
as the curved prongs such as illustrated in FIG. 8a. A pair of
second or subordinate anchor means configured as subordinate prongs
57 are mounted in the shelf braces 55. The curved prongs or shanks
have a fixed radius of curvature R2, which is preferably about the
thickness or less of the wallboard into which it will be inserted.
The wall-engaging portion 9 has a wall confronting region 9.1 with
a flat wall facing and engaging surface 9.3 and a uppermost wall
engagement point 9.4 configured as edge or corner is this
embodiment.
[0083] FIG. 19 illustrates how the appurtenant 53 is attached to
the outside facing surface 2. The arcuate prongs 54 piece the
surface of wallboard as in FIG. 19 and is then rotated downwardly
about corner 9.4, the upper most portion of the wall engaging
portion, until the lower subordinate prongs are inserted and the
shelf is seated in the fixed seating position illustrated in FIG.
20.
[0084] FIGS. 21 and 22 show embodiments of the present invention
used to mount a appurtenant configured as a toothbrush holder to
the wallboard. The holder base body 59 has integral or fixed
therein arcuate prongs 60 and a lower subordinate anchor means
configured as a screw 61. The top edge 9.4 is positioned with
respect to the prongs 60 to provide positional guidance and wall
utilization for locating and attaching inserting the prongs. The
prongs are inserted as illustrated in FIG. 22 and are rotatably
lowered about the uppermost point 9.4, configured as a corner, into
seating position flush against the wall. The subordinate lower
anchor means, the screw 61 is then inserted to lock the unit in
place.
[0085] FIGS. 23 through 25 show embodiments of the present
invention used to mount a towel bar holder to wallboard. The
appurtenance is configured as a bracket 37 with integral arcuate
prongs that pierce the wall surface 2. Note that such attachment
can be accomplished without using the uppermost point of the wall
engagement portion of the bracket and still obtain an attachment of
high integrity. The subordinate anchor means of the screw 62
secures the bracket in place and the towel bar holder 63 is
attached conventionally with set screw 64. Note that with an
appurtenance as such it is possible that the arcuate prongs can
extend around more than the 1/4 rotation as illustrated by the
extended point 39.1.
[0086] The present invention is an anchor that can be used to
fasten objects to a hollow or non-hollow wall vertical or at
surface constructed using sheetrock, drywall, gypsum, wallboard, or
other easily pierced material. The piercing of the surface is
accomplished by a point stamped or machined onto the end of a
curved flat wire, strip, or sheet with a substantially rectangular
or elliptical cross section with the major axis being orthogonal to
the radius of the curve in the wire. The wire is bent with such a
radius that when the wire is fully inserted into the vertical or
flat surface material the flat face of the wire proximal to the
pointed tip rests against the outside of the surface 3 opposite
that of initial penetration 2 by the wire as shown in FIG. 1.
[0087] When the anchor is inserted into the drywall 1 or other
surface material, it follows an arc like path, piercing the second
opposite surface from inside the material in a. tangential manner,
such that it does not require a hollow cavity in which to enter
behind the wallboard. The arched path by which the anchor
penetrates provides additional holding capability, making it more
difficult to remove the anchor by pulling it directly out of the
surface in which it is anchored. Generally the anchor is positioned
on installation such that the arc in the anchor points away from
the load or opposing anchor force. Either a similarly curved
anchor, or a straight pin, nail or screw is used below the anchor
in a vertical installation to provide vertical support keeping the
anchor located. Similarly horizontal installations require opposing
force anchors co-joined to the device being secured.
[0088] The radius of the inner arched surface of the anchor can be
anything up to approximately the same size as the thickness of the
material that the anchor is being attached to. When the material
thickness and anchor radius are approximately the same, this can
result in the inner arched surface of the anchor piercing the
surface opposite that of initial penetration and coming to rest on
the surface opposite with the mating arched flat surface of the
anchor and the surface opposite being substantially coincident and
coplanar at the point of interface between them, resulting in
evenly distributed pressure across the interface and reduces the
probability of the anchor being pulled through the wallboard
material upon loading. In cases where the anchor shank length
and/or radius is less than the wallboard material thickness, the
anchor simply lodges within the wallboard material as shown in
FIGS. 5 and 17 with the load force on the anchor distributed over
the flat face of the shank interface with the wallboard material.
In this manner the anchor of the present invention does not require
a cavity behind the wallboard, unlike the prior art which does
require a hollow or cavity.
[0089] Important aspects of invention is that appurtenances
weighing more that one pound are readily supported. Such
appurtenance may have a center of gravity more than 2 inches from
the wall surface. Preferred embodiments will support appurtenances
weighing much more than 5 pounds. The arcuate prong is preferably
less than 1.5 inches measured along its lower profile in preferred
embodiments, less that 1.25 inches in more preferred embodiments
and less than 1.0 inches in other preferred embodiments.
[0090] The anchor is installed either in opposition to another
anchor co-joined to the device to be anchored to the surface, or in
the case of a vertical surface the anchor may be installed with a
straight connecting device in place of an opposing anchor. The
vertical surface installation would typically be done with the
anchor tip pointing upwards upon completion of the installation,
and may use a straight pin, tack, nail, or screw to secure the
bottom of the object being anchored to the surface.
[0091] The radius flat face anchor of the present invention can be
integrated with a tack, nail, screw, or some other fastening device
permitting direct use with any number of items to be secured to a
wallboard wall, ceiling, or surface.
[0092] Embodiments of the present invention of the wallboard anchor
with curved shank, the shank radius does not need to be fixed in
that it can vary through the curve profile of the anchor, from
twice the wire diameter to infinite (i.e. straight) at certain
portions of the shank.
[0093] As will be apparent to those skilled in the art in the light
of the foregoing disclosure, many alterations and modifications are
possible in the practice of this invention without departing from
the spirit or scope thereof.
* * * * *