SURFACE ATTACHMENT DEVICE

Abstract

Disclosed is a surface attachment device that can be bonded to a surface. The surface attachment device may store, mix and dispense adhesive to form a bond with a surface. Also disclosed are accessories for use with the surface attachment device and a method of attaching accessories to a surface using the surface attachment device.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 61/160,057 filed Mar. 13, 2009.

FIELD

The present disclosure relates generally to a device that can be permanently bonded to a surface to provide a mounting point for accessories.

BACKGROUND

The construction of commercial and residential structures often requires the use of structural supports that are combined to form a load bearing framework. These structural supports are typically sturdy rectangular, square, and/or planar members having dimensions which are often many inches in width and which incorporate substantial surfaces meeting at right angles. The structural supports are commonly constructed of such materials as steel, aluminum, iron and concrete. The supports may be covered with cementitious materials or with a finishing material such as wallboard, paneling, fireproofing, insulation, and/or other materials. The finishing material can be installed directly to the structural supports or with the use of intermediate framing elements, for example steel or wood studs.

It is often necessary to anchor objects to a surface such as that of the framework, finishing material, ceiling, floor, etc. For example, electrical boxes, cable supports, HVAC duct supports and pipe supports are anchored to the load bearing framework, such as by welding, clamping or fastening. Lights, electrical boxes, hooks, shelves, etc. can be anchored to finishing material, for example by specialized wall fasteners.

However, the use of welding requires specialized equipment and highly trained personnel. Drilling holes through steel supports is difficult and time consuming. Mechanical fasteners are expensive, require tools to install and do not always anchor securely in finishing material. Mechanical fasteners are also difficult to use in some materials such as ceramics, masonry or stone without damage. Adhesive fasteners such as COMMAND strips available from 3M are very limited in load capacity. Thus, there remains a need for a new device and system that can anchor accessories to a surface.

SUMMARY

Briefly, one aspect of the disclosure provides a surface attachment device that can be bonded to a surface to provide an accessory mounting point. One aspect of the disclosure provides a surface attachment device that stores, mixes and dispenses adhesive to form a bond with a surface. One aspect of the disclosure provides a system comprising an accessory mounted to a surface attachment device.

In advantageous embodiments the disclosed surface attachment device provides many benefits over conventional anchoring systems. The surface attachment device is simple to use and does not require drilling or mechanical fastening. The surface attachment device contains any needed adhesive internally and does not require external containers of adhesive. The surface attachment device can provide an accessory mounting point on any bondable surface, interior or exterior. Bondable surfaces include wood, metal, ceramic, masonry, stone, polymeric and composite such as fiberglass reinforced plastic. The surface attachment device can be self fixturing. Adhesive compositions such as structural epoxy compositions can provide the surface attachment device with a substantial bond to the surface in minutes allowing high load capacity. The same surface attachment device can be used with different accessories in different applications.

In general, unless otherwise explicitly stated the disclosed materials and processes may be alternately formulated to comprise, consist of, or consist essentially of, any appropriate components, moieties or steps herein disclosed. The disclosed materials and processes may additionally, or alternatively, be formulated so as to be devoid, or substantially free, of any components, materials, ingredients, moieties, species and steps used in the prior art compositions or that are otherwise not necessary to the achievement of the function and/or objective of the present disclosure.

When the word “about” is used herein it is meant that the amount or condition it modifies can vary some beyond the stated amount so long as the function and/or objective of the disclosure are realized. The skilled artisan understands that there is seldom time to fully explore the extent of any area and expects that the disclosed result might extend, at least somewhat, beyond one or more of the disclosed limits. Later, having the benefit of this disclosure and understanding the concept and embodiments disclosed herein, a person of ordinary skill can, without inventive effort, explore beyond the disclosed limits and, when embodiments are found to be without any unexpected characteristics, those embodiments are within the meaning of the term about as used herein.

BRIEF DESCRIPTION OF THE DRAWINGS

References to element locations in the figures such as “top” are informational and not necessarily representative of that element in use. Referring now to the drawings wherein like elements are numbered alike in the several Figures:

FIG. 1 is a top and side perspective view of one embodiment of a surface attachment device.

FIG. 2 is a top view of the body of the device of FIG. 1 showing pouches of curable composition on the fixed plate within the body.

FIG. 3 is a bottom and side perspective view of the device of FIG. 1 showing PSA adhesive bonded to the bonding cavity, the mixer disposed within the bonding cavity and bonding end.

FIG. 4 is a top and side perspective view showing of the device of FIG. 1 with the drive mechanism threadedly engaged within the body.

FIG. 5 is a side view, partly in section, of one embodiment of a surface attachment device.

FIG. 6 is a perspective view of the rear and side of the device of FIG. 5.

FIG. 7 is a perspective view of the front and side of the device of FIG. 5.

FIG. 8 is a perspective view of the drive ring of the device of FIG. 5.

FIG. 9 is a schematic side view of one embodiment of an accessory.

FIG. 10 is a schematic side view of one embodiment of an accessory.

FIG. 11 is a schematic side view, partly in section and partly in phantom, of one embodiment of an accessory.

DETAILED DESCRIPTION

With reference to the embodiment shown in FIG. 1 the surface attachment device 10 comprises a hollow body 12 having a retaining end 14 and an opposing bonding end 16. An interior wall 18 of the body 12 defines an interior space 22 therein. The interior wall 18 adjacent the retaining end 14 can be provided with an engaging portion to interengage with an accessory, for example, threads, friction fit, catch, etc. As shown best in FIG. 3 the body 12 may comprise a hollow base 24 adjacent the bonding end 16. The base 24 is sealingly engaged to the remainder of the body 12 for rotational movement of the base 24 with respect to the body 12. Sealing engagement of the base 24 and body 12 can be achieved by, for example, having an outwardly projecting flange 26 of the body retained within a recess of the base 24. Optionally, a purge aperture 28 can provide a fluid connection between the interior space 22 and the exterior of the base 24 or body 12. The device 10 can be any convenient shape and thickness suitable for its intended use. In one variation the device 10 is circular and about two to four inches in diameter and one half to two inches thick. In other variations the device 10 can be smaller or larger as desirable to the intended application.

With reference to FIG. 1, plate 32 is disposed within the base 24 or the body 12. Advantageously, the plate 32 is fixed substantially perpendicularly to the body internal wall 18 between the bonding end 16 and the retaining end 14. The fixed plate 32 can be skeletal or define one or more apertures 34 therethrough. The portion of the interior space between the fixed plate 32 and the retaining end 14 is a body cavity 36. The portion of the interior space between the fixed plate 32 and the bonding end 16 is a bonding cavity 38. If used, the purge apertures 28 can advantageously provide a fluid connection between the bonding cavity 38 and the body exterior.

In some variations an adhesive 42 is disposed adjacent the bonding end 16 to temporarily fix or secure the attachment device 10 to a surface. Advantageously, the adhesive 42 is a pressure sensitive adhesive such as acrylic or rubber based PSA or foam backed PSA. A release liner 44 can be disposed over the exterior surface of the adhesive 42 to prevent inadvertent bonding of the adhesive 42 to a surface. The release liner 44 is removed when bonding the device 10 to a surface. In one advantageous variation shown best in FIG. 3 the adhesive 42 is bonded to the base 24.

In some variations a mixer 46 is disposed in the bonding cavity 38. Movement of the mixer 46 helps stir curable composition in the bonding cavity 38. In one advantageous variation shown in FIG. 3 the mixer 46 is disposed on the fixed plate 32 to project into the bonding cavity 38 and is movable within the bonding cavity 38 by rotation of the body 12 with respect to the base 24.

A drive plate 50 is disposable in the body cavity 36 for axial movement between the retaining end 14 and the fixed plate 32. Advantageously, there is a minimum clearance between the drive plate 50 and the body interior wall 18 to allow axial movement of the drive plate 50 but minimize escape of curable composition between the drive plate 50 and the body interior wall 18.

In the embodiment shown in FIG. 1, the drive plate 50 is an integral part of a drive mechanism 52 comprising an externally threaded plug having an actuation end 54 opposing the drive plate 50. The exterior plug threads are interengagable with the internal body threads so that the drive mechanism 52 can be threadedly engaged with the body 12. Threaded engagement of the drive mechanism 52 with the body 12 will force the drive plate 50 axially toward the fixed plate 32. Reversed rotation of the drive mechanism 52 will move the drive plate 50 axially away from the fixed plate 32. The actuation end 54 can include a tool engagement portion 56 such as a slot, internal shoulders or external shoulders to allow selective actuation of the drive mechanism by a tool such as a screwdriver, wrench, socket, etc.

A curable composition is enclosed or sealed in a package. The packaged curable composition 60 can be disposed in the interior space 22, advantageously in the body cavity 36 between the fixed plate 32 and the drive plate 50. The package 60 can be designed so that axial movement of the drive plate 50 toward the fixed plate 32 breaks the package 60 and extrudes the contents through the fixed plate apertures 34 into the bonding cavity 38. In another variation a user opens or punctures the package 60 to free the composition. Subsequent axial movement of the drive plate 50 toward the fixed plate 32 extrudes the composition through the fixed plate apertures 34 into the bonding cavity 38.

The parts of the surface attachment device 10 can be made from any material having suitable strength for the application and chemical resistance to the chosen curable composition. Polymers such as PVC; polyolefin, nylon and acetal can be used with PVC being advantageous. Metals can also be used for some or all of the components.

With reference to the embodiment shown in FIGS. 5 to 8 the surface attachment device comprises a hollow, disk shaped body 68 having a retaining end 70 shown in FIG. 7 and an opposing bonding end 72 shown in FIG. 6. The cylindrical exterior surface 74 of the body 68 is threaded 76. The body 68 has an internal wall 78 defining an internal space 80 therein. Optionally, one or more purge apertures 84 can radially penetrate from the body space 80 to the body exterior adjacent the bonding end 72. The device 10 can be any convenient diameter and thickness suitable for its intended use. In one variation the device 10 is about four inches in diameter and one half inch thick. In other variations the device 10 can be smaller or larger as desirable to the intended application.

A drive plate retainer 86 as shown best in FIG. 5 may optionally extend radially inwardly from the retaining end 70.

A plate 88 is disposed within the body space 80. Advantageously, the plate 88 is fixed substantially perpendicularly to the body internal wall 78 within the body space 80 between the bonding end 72 and the retaining end 70. The fixed plate 88 is skeletal or defines one or more apertures 90 therethrough. The portion of the body space between the fixed plate 88 and the retaining end 70 is a body cavity 92. The portion of the body space 80 between the fixed plate and the bonding end 72 is a bonding cavity 94. If used, the purge apertures can provide a fluid connection between the bonding cavity and the body exterior.

In some variations an adhesive 98 is disposed adjacent the bonding end 72 to temporarily fix or secure the attachment device 10 to a surface. Advantageously, the adhesive 98 is a pressure sensitive adhesive such as acrylic or rubber based PSA or foam backed PSA. A release liner 100 can be disposed over the exterior surface of the adhesive 98 to prevent inadvertent bonding of the adhesive 98 to a surface. In one advantageous variation shown best in FIG. 5 the adhesive 98 is bonded to the fixed plate and optionally to the body internal wall 78 and extends beyond the bonding end 72.

A drive mechanism 102 comprises a drive ring 104 and drive plate 106. In the variation shown best in FIG. 5, the drive plate 106 is disposed in the body cavity 92 for axial movement between the retaining end 70 and the fixed plate 88. The drive plate 106 is retained within the body 68 by the fixed plate 88 and the drive plate retainer 86. Advantageously, there is a minimum clearance between the drive plate 106 edge and the body internal wall 78 to allow axial movement of the drive plate 106 but minimize escape of curable composition between the drive plate 106 and the body internal wall 78.

In some variations a mixer 110 is disposed within the bonding cavity 94 between the bonding end 72 and the fixed plate 88. Advantageously, the mixer 110 is movable within the bonding cavity 94. In one variation shown best in FIG. 5 the mixer 110 is connected, such as by an axle 112, to an actuation device 114 disposed externally to the drive plate 106. The actuation device 114 can be, for example, a knob to allow selective actuation of the mixer by a user's fingers. The actuation device 114 can include a tool engagement portion 116 such as a slot, internal shoulders or external shoulders to allow selective actuation of the mixer 110 by a tool such as a screwdriver, wrench, socket, etc. Advantageously the tool engagement portion 116 is a one way device allowing the tool to rotate the actuation device 114 in only one direction.

The parts at the attachment device 10 can be made from any material having suitable strength for the application and chemical resistance to the chosen curable composition. Polymers such as PVC; polyolefin, nylon and acetal can be used with PVC being advantageous. Metals can also be used for some or all of the components.

A packaged curable composition 120 is disposed in the body cavity 92 between the fixed plate 88 and the drive plate 106. The package 120 can be designed so that axial movement of the drive plate 106 toward the fixed plate 88 breaks the package 120 and extrudes the contents through the fixed plate apertures 90 into the bonding cavity 94. In a variation a user opens punctures the package 120 using a tool inserted through the fixed plate apertures 90. Subsequent axial movement of the drive plate 106 toward the fixed plate 88 extrudes the curable composition through the fixed plate apertures 90 into the bonding cavity 94.

With reference to FIG. 8, the cylindrical drive ring 104 comprises a hollow, disk shaped body 122 having an exterior surface 124 connecting a drive end 126 and an opposing starting end 128. The drive ring 104 has an internal wall 130 defining a cylindrical space therein. The internal wall 130 defines threads 138 thereon. A plurality of angularly spaced shoulders 134 project radially inwardly and axially toward the starting end 128 from the drive end 126. The radial and axial projection of the shoulders 134 defines a clearance aperture 136 in each shoulder 134. The drive ring threads 138 are interengagable with the body threads 76 so that the drive ring 104 can be threadedly engaged with the body 68 to move the shoulders 134 into contact with the drive plate 106. Continued threaded engagement of the drive ring 104 with the body 68 will force the drive plate 106 axially toward the fixed plate 88. The clearance aperture 136 allows the shoulders 134 to avoid contact with the body retaining end 70 while maintaining contact with the drive plate 106 as the drive ring 104 moves along the body 68. Reversed rotation of the drive ring 104 will disengage the shoulders 134 from the drive plate 106 and subsequently disengage the drive ring 104 from the body 68. In one variation the drive ring 104 includes a driver tool 140 such as a rod or bar diametrically spanning the drive ring. The driver tool 140 can interengage with the actuation device tool engagement portion 116 so that threaded engagement of the drive ring 104 with the body 68 will simultaneously rotate the actuation device 114. Use of a one way engagement portion allows rotation of the actuation device 114 by the drive ring 104 in only one direction.

The curable composition in any embodiment is not limited and can be selected based on application. For example, curable compositions based on acrylics, urethanes or epoxy compositions are useful with the surface attachment device. The curable composition may be a one part composition or a two part composition in separate packages. A two part structural epoxy composition can advantageously provide a substantially cured bond between the surface attachment device and a surface that will support hundreds or thousands of pounds. Typically, the amount of curable composition will be preselected to allow filling of the bonding cavity to a level sufficient to bond the attachment device to a surface without excess composition remaining in the body cavity.

A user threadedly engages a drive mechanism or drive ring with a body. If needed, the user can open or puncture the curable composition package disposed within the body cavity prior to engagement. The release liner is removed and the adhesive is placed in contact with a preselected portion of surface to temporarily bond the attachment device to the surface. The drive mechanism or drive ring is rotated to axially move the drive plate toward the fixed plate. As the drive plate moves axially toward the fixed plate curable composition is forced through the fixed plate apertures and fills the bonding cavity to contact the surface.

Movement of the mixer can mix curable composition in the bonding cavity. This is helpful to mix both parts of a two part curable composition. In some variations excess curable component is purged through the purge apertures. Once the curable composition fills the bonding cavity and contacts the surface the drive mechanism or drive ring may be removed from the attachment device. Curing of the curable component in the bonding cavity permanently bonds the attachment device to the surface.

The attachment device can be in the form of a self contained kit containing a packaged curable composition held within the body between the bonding end and the drive plate. A user can remove the attachment device from its packaging; temporarily secure the device to a desired surface; and move the drive plate toward the bonding end to dispense curable composition against the surface. Once the composition has cured accessories can be mounted to the body. A self contained kit is advantageous as it contains all components necessary to provide a mounting point on a surface. A user does not have to purchase separate hardware and compositions; mix and apply compositions from large containers; or store excess adhesive compositions.

Once the attachment device of any variation is permanently bonded to the surface an accessory 144 can be mounted to the body 12, 68. The accessory 144 provides a link or coupling between the bonded body and an object 146. Accessory 144 design is limited only by the need to mount the accessory 144 to the body 12, 68 and link or support the object 146. The accessory 144 can comprise, for example, an internally or externally threaded connector, a hook, a mounting slot, a loop, a rod holder, a box, a wire holder, a support such as for bracing, shelving, posts, ventilation, ducting, piping, wiring, etc. Multiple devices arranged in a line may be used with a respective number of accessories to provide a line of support such as for upright fencing, shelves, piping, electrical raceways, ductwork, etc. Multiple devices arranged in an array may be used with a respective number of accessories to provide a plane of support such as for curtain walls.

The accessory can be mounted by any convenient method, for example threaded engagement of the accessory with internal or external threads of the body, frictional engagement of the accessory with the body, bonding or mechanical fastening of the accessory to the body, etc. Threaded engagement of the accessory to the attachment device is simple and advantageously allows replacement of one accessory with a different accessory as needs change. FIG. 9 illustrates one embodiment of an accessory 144 having a threaded portion 148 for interengagement with a correspondingly threaded body 12. An arm 150 extends axially from the threaded portion 148. The arm 150 defines a linear surface 152 such as for supporting a shelf 154. FIG. 10 illustrates one embodiment of an accessory 144 having a threaded portion 148 for interengagement with a correspondingly threaded body 12. An arm 158 extends axially from the threaded portion 148 terminating in a ring 160. The ring 160 diameter may be fixed or adjustable. The ring 160 can advantageously support objects 146 such as pipes, wires, cable, etc threaded therethrough. FIG. 11 illustrates one embodiment of an accessory 144 having a threaded exterior portion 148 for interengagement with a correspondingly threaded body 12. The portion 148 defines an internally threaded cavity 164. Varying the size of the internally threaded cavity 164 allows use of the bonded body 12 with threaded fasteners of different sizes.

While preferred embodiments have been set forth for purposes of illustration, the foregoing description should not be deemed a limitation of the disclosure herein. Accordingly, various modifications, adaptations and alternatives may occur to one skilled in the art without departing from the spirit and scope of the present disclosure.

Claims

1. A device for attaching to a surface to transfer a load to the surface, comprising:

a hollow body having a bonding end opposing a retaining end, an exterior surface and an internal wall defining an internal cavity;

an adhesive disposed adjacent the bonding end for temporarily securing the device to a surface;

a fixed plate disposed within the body intermediate the bonding end and the retaining end, the fixed plate defining a plurality of apertures therethrough; and

a drive plate disposed within the body adjacent the retaining end for axial movement between the retaining end and the fixed plate.

2. The surface attachment device of claim 1, wherein the fixed plate is generally perpendicular to the internal wall.

3. The surface attachment device of claim 1, wherein the fixed plate is a disk secured generally perpendicularly to the internal wall.

4. The surface attachment device of claim 1, comprising a curable composition stored within the hollow body.

5. The surface attachment device of claim 1, wherein a bonding cavity is defined between the fixed plate and bonding end and comprising a curable composition stored intermediate the fixed plate and the drive plate for movement through the fixed plate apertures into the bonding cavity.

6. The surface attachment device of claim 1, wherein the hollow body comprises an engagement portion.

7. The surface attachment device of claim 1, wherein the hollow body comprises a threaded interior surface.

8. The surface attachment device of claim 1, further comprising a mixer between the fixed plate and the bonding end.

9. The surface attachment device of claim 1, further comprising a mixer intermediate the fixed plate and the bonding end and an actuator external to the drive plate for selectively moving the mixer.

10. An accessory for mounting to the surface attachment device of claim 1.

11. An accessory for mounting to the surface attachment device of claim 1, comprising a hook, a mounting slot, a loop, a holder, a box, a wire holder and a support.

12. An accessory, comprising a portion mountable to the surface attachment device of claim 1 attached to a portion capable of supporting an object.

13. A kit for providing a surface anchor point, including:

a surface attachment device, comprising: a hollow body having a bonding end opposing a retaining end, an exterior surface, an internal wall defining an internal cavity and a threaded portion, an adhesive disposed adjacent the bonding end for temporarily securing the device to the surface, a retainer disposed within the body intermediate the bonding end and the retaining end, the retainer defining an aperture therethrough, curable composition disposable within the hollow body; and a drive mechanism comprising a drive end, an actuation portion and a threaded portion interengagable with the body threaded portion, wherein threaded engagement of the drive mechanism and body axially moves the drive plate toward the fixed plate; and

an accessory mountable to the surface attachment device and comprising an anchor point.

14. The surface attachment kit of claim 13, wherein the drive mechanism threaded portion comprises a threaded internal wall and comprising a plurality of internally projecting drive shoulders, the drive shoulders capable of moving the drive plate axially from the retaining end toward the fixed plate when the drive ring threaded portion is engaged with the body threaded portion.

15. The surface attachment kit of claim 13, wherein the drive plate is integral with the drive mechanism and the drive mechanism threaded portion comprises a threaded exterior surface.

16. The surface attachment kit of claim 13, wherein the adhesive element disposed adjacent the bonding end is in the form of a pressure sensitive adhesive.

17. The surface attachment kit of claim 13, further comprising a mixer between the fixed plate and the bonding end.

18. The surface attachment device of claim 13, further comprising a mixer intermediate the fixed plate and the bonding end and an actuator external to the drive plate for selectively moving the mixer.

19. The surface attachment device of claim 13, wherein a bonding cavity is defined between the fixed plate and bonding end and curable composition is stored intermediate the fixed plate and the drive plate for movement through the fixed plate apertures into the bonding cavity.

20. A surface attachment device, comprising:

a body having a bonding end opposing a retaining end, an exterior surface and an internal wall defining an internal cavity;

a drive plate disposed within the internal cavity adjacent the retaining end for axial movement toward the bonding end; and

a curable adhesive composition sealed within a package to minimize curing of the adhesive composition until the package is opened, the package held within the cavity between the bonding end and the drive plate.