Wallboard appurtenance attachment
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.
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 INVENTIONThis 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 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
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
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.
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.
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.
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.
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.
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.
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.
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
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
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
In a preferred embodiment, the appurtenance includes the arcuate prong wall-engaging portion integral with or fixedly attached thereto.
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.
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
Referring to
The shank shown in
The point 7 of the anchor may or may not pierce the second surface 3 of the wallboard 1 as shown in
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.
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.
Referring specifically to
Referring to
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
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
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
For heavier applications the wallboard anchor of the present invention may take the form of screw mount shank 25 as shown in
In many applications, such as hanging picture frames or shelving on wallboard as shown in
Referring again to
The invention includes methods of manufacturing wall anchors and methods of manufacturing appurtenances with integral or attached wall anchors.
The embodiments as illustrated in
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.
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 ½ inch wallboard a prong with a radius of curvature of about ½ inch or less and an upper most pivot point on the wall engagement portion of about ½ 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.
Referring to
Referring to
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
For anchoring applications on both horizontal and vertical surfaces the dual anchor leaf embodiment of the present inventions shown in
Referring to
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
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.
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
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.
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.
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.
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.
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.
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.
Type: Application
Filed: Feb 14, 2007
Publication Date: Oct 11, 2007
Inventors: Kerry Baran (Kelowna), Herbert Woiczyk (Summerland)
Application Number: 11/706,839
International Classification: A47F 5/08 (20060101);