NZ568440A - A fastening devise that is supported by the wall and a member on the other side of the wall cavity - Google Patents

Abstract

A fastening means for securing an object to a plurality of support members is disclosed. At least a portion of the fastening means is inserted into a hole formed in a first support member (60) and then fastened to the second support member (80). The fastening means comprises: an elongate body (30) capable of being reduced such that the combined length of the elongate body (30) and exposed part of the distal end (40) substantially corresponds to the distance between the outside face of the first support member (60) and second support member (80) and is substantially cylindrical, a proximate end adapted to receive an attachment means, and a distal end (40) adapted for fastening to a second support (80) member in which the largest diameter of the distal end (40) of the fastening means is less than the diameter of the elongate body (30) at the point at which the distal end (40) joins to the elongate body (30). A hook (100) or similar is able to be attached to the first support member (60) e.g. a wall and be able to hold a greater weight due to the increased support.

Description

James & Wells Ref: 233394/75 *10055775270* PATENTS FORM NO. 5 Fee No. 4: $250.00 PATENTS ACT 1953 COMPLETE SPECIFICATION A WALL FASTENER I Toni Lendl, a New Zealand citizen of 98 Victoria Street, Onehunga, Auckland, New Zealand hereby declare the invention for which I pray that a patent may be granted to me, and the method by which it is to be performed to be particularly described in and by the following statement: Intellectual Property Office of N.Z. 1 9 MAY 2008 RECEIVED James & Wells Ref: 233394/75 A WALL FASTENER TECHNICAL FIELD This invention relates to a fastening means. In particular, the principles of the present invention relate to an improved means for fastening objects to a hollow support structure such as a wall.

BACKGROUND ART Wall fasteners are well known for providing means to secure objects to interior wall surfaces. These fasteners are commonly used for securing brackets, picture hooks, curtain rails and other objects that need to be securely fastened to a wall.

Internal walls are generally formed of an internal solid frame with an outer covering of a less robust material, such as wallboard. Between the solid frame and the outer covering it is common to have a space that may be filled with insulation or similar materials.

It is commonly known in the art to anchor objects to an outer wallboard using a variety of different fastening means, in particular screws or nails. However, one disadvantage of anchoring the attachment only into the outer wallboard is that, once a weight is attached to the fastening means (for example a picture or curtain rail) the hole gradually enlarges due to the combined effects of the softness of the board and the weight of the object fastened via the fastening means to the wall. Thus fastening means secured into wallboard in this fashion have been known to pull out completely from the wall, leaving unwanted holes and/or cracks in the wall, and potentially damaging the object so fastened. 2 James & Wells Ref: 233394/75 There are a number of products available that attempt to address the above problem. These fasteners provide a means to spread the load of the object to be attached to the wall over a wider area, using legs, sleeves or toggles that become fixed on insertion of the fastener into the wall.

Mechanical Plastics Corporation holds a number of patents covering fastening devices and wall anchors, in particular NZ 221637, NZ 236899, NZ 235900 and NZ 512938. New Zealand Patent No. 221637 describes a fastening device wherein the anchoring element can move between open and closed positions to provide further support to the anchor, while NZ 236899 and NZ 236900 disclose wall anchors with outstretched arms to increase the load bearing strength of the anchor. New Zealand Patent No. 512938 describes methods for anchoring elements using a screw together with a plastic extrudable plug into a wall or substrate.

These products go some way to reducing the stress on the wall board. However as they are still reliant on the strength of the board itself for support they have limited application when the object to be fastened to the wall is above a weight which exceeds the load bearing capacity of the wallboard.

It is an object of the present invention to provide a method and apparatus for fastening objects to walls that overcomes the above disadvantages, or at least to provide the public with a useful choice.

All references, including any patents or patent applications cited in this specification are hereby incorporated by reference. No admission is made that any reference constitutes prior art. The discussion of the references states what their authors assert, and the applicant reserves the right to challenge the 3 accuracy and pertinency of the cited documents. It will be clearly understood that, although a number of prior art publications are referred to herein, this reference does not constitute an admission that any of these documents form part of the common general knowledge in the art, in New Zealand or in any other country.

Further aspects and advantages of the present invention will become apparent from the ensuring description which is given by way of example only.

DISCLOSURE OF INVENTION According to one aspect of the invention there is provided a means for fastening an object to two support members, wherein at least a portion of the fastening means is inserted within a hole formed in a first support member, said fastening means comprising; • an elongate body; • a proximate end adapted to receive an attachment means; and • a distal end adapted for fastening to a second support member; characterised in that the length of the elongate body is capable of being reduced such that the combined length of the elongate body and exposed part of the distal end substantially corresponds to the distance between the first and second support members.

According to a second aspect of the invention there is provided a method for securing an object to two support members, said method comprising: 4 • inserting the distal end of a fastening means through a hole in a first support member; wherein the fastening means comprises; an elongate body; a proximate end adapted to receive an attachment means; and a distal end adapted for fastening to a second support member; • fixing the distal end of the fastening means into a hole in the second support member; • reducing the length of the elongate body such that the proximate end of the elongate body lies substantially planar to the outside face of the first support member; and • fixing an object to the proximate end of the fastening means via an attachment means secured within the elongate body of the fastening means.

As used in this specification, the term "support member" refers to any substantially planar element of a wall structure. Preferably the first support member is the outer wall board of a wall and the second support member a part of the underlying framework of the wa! I.

INTELLECTUAL PROPERTY OFFICE OF f\U. - 9 OCT 2008 received James & Wells Ref: 233394/75 Throughout the present specification it should be understood that the phrase "distance between the first and second support members" is taken to be the shortest distance between any opposing part of the second support member and the area of the first support member in which the hole for insertion of the fastening means has been formed.

The terms "adjusted" or "adjustable" refer to any means by which the length of the elongate body may be shortened. In preferred embodiments the elongate body may be cut to an appropriate length to suit the distance between the first and second support members. However, this should not be seen as limiting. For example in an alternative form of adjustment the elongate body may be cut, torn, severed, or snapped along weakened joins located at discrete points along the elongate body.

The term "weakened joins" shall mean perforations, cut lines which do not extend all the way through the material, a thinner area of material or other similar weakening of the elongate body.

Preferably, the elongate body of the fastening means is substantially cylindrical in shape. 6 James & Wells Ref: 233394/75 Preferably, the elongate body and distal end of the fastening means are integrally formed. Preferably the proximate end of the elongate body is adjusted by cutting the elongate body.

More preferably, the elongate body is configured with weakened joins at discrete intervals along the length of the body which can be severed to adjust the length of the body.

Preferably, the elongate body contains a marking at its proximate end, indicating the entry position of an attachment means.

In an alternative preferred embodiment of the invention, the elongate body contains an aperture, adapted to receive an attachment means, such as a bolt.

Preferably the aperture is sleeved with an insert configured to receive an attachment means.

Preferably, the distal end of the fastening means has a diameter less than the diameter of the elongate body at the point at which the distal end joins to the elongate body.

Preferably, the elongate body and distal end of the fastening means are integrally formed from a rigid plastics material. 7 James & Wells Ref: 233394/75 Preferably, the distal end of the fastening means is in the form of a tapered shaft.

Still more preferably, the distal end of the fastening means is in the form of a tapered screw.

In a further preferred embodiment, when the distal end of the fastening means is a tapered screw, a portion of the elongate body is shaped to assist rotation of the fastening means.

Preferably, the elongate body is shaped to receive a co-operating means of rotation, such as a screw-driver, spanner, socket, wrench or gripping implement. Alternatively, the portion of the elongate body shaped to receive a co-operating means comprises an aperture in the proximate end of the elongate body.

BRIEF DESCRIPTION OF DRAWINGS Further aspects of the present invention will become apparent from the ensuing description which is given by way of example only and with reference to the accompanying drawings in which: Figure 1 shows a side view of a fastening means according to a preferred embodiment of the invention; Fioure 2 shows a plan view of the distal end of the fastening means as shown in Figure 1; 8 James & Wells Ref: 233394/75 Figure 3 Figure 4 Figure 5 Figure 6 BEST MODES FOR CARRYING OUT THE INVENTION Figures 1-4 show side, plan and perspective views of a fastening means 10 according to a preferred embodiment of the invention. The fastening means 10 includes an elongate body 30, with a proximate end 20 and a distal end 40. The distal end 40 of the elongate body 30 comprises a fixing means in the form of an integrated tapered shaft 40 for fixing the fastening means 10 to an inner frame of a wail as discussed in more detail below.

In the preferred embodiment, the distal end 40 is integrally formed with the elongate body 30 from a rigid plastics material. It will however be appreciated by those skilled in the art that the fastening means 10 can be made from other suitably rigid materials known in the art that are able to be cut or trimmed.

In the preferred form of the invention the elongate body 30 is formed in a cylindrical shape as shown in Figure 4. It will be understood that this shows a plan view of the proximate end of the fastening means as shown in Figures 1 and 2; shows a perspective view of the fastening means as shown in Figures 1-3; shows a side view of the fastening means as shown in Figures 1-4 when inserted into a wall prior to adjusting the length of the elongate body; shows a side view of the fastening means as shown in Figures 1-4 when inserted into a wall and installed with an attachment means and a bracket. 9 James & Wells Ref: 233394/75 configuration is not intended to be limiting, and the elongate body 30 may be formed in other shapes such as an elongate square, rectangular or semicircle for example.

It is an essential feature of the invention that the elongate body 30 is adjustable so as to substantially correspond to the distance between the first and second support members of a wall. The distance between first and second support members of a wall (for example the outer wall board and the inner wall frame) differs between buildings, and it is often not known what this distance is until a hole is made in the first support member. Therefore, the elongate body 30 of the fastening means 10 must be adjustable so as to fit substantially within the space between two support members.

In a preferred embodiment, the elongate body 30 is formed from plastic that is able to be cut or trimmed. Once the distance between the first and second support members of a wall has been ascertained, the elongate body 30 can be cut, snapped or torn at the appropriate length so that it is substantially the same length as the distance between the first and second support members. It is envisaged that the adjustment means may include weakened joins that are formed at discrete distances along the elongate body 30, that can be easily severed or snapped to the desired length.

The distal end 40 of the fastening means 10 is preferably in the form of a tapered shaft, integrally formed with the elongate body 30, as shown in figures 1-4. The distal end 40 holds the elongate body 30 in position between the first and second support members of the wall by fixing into the solid frame of the second support member.

James & Wells Ref: 233394/75 While preferably in the form of a tapered shaft, it is envisaged that the distal end 40 may be formed in other configurations that enable the fastening means 10 to be fixed to the second support member, for example a tapered screw.

It can be seen from Figures 1-4 that in the preferred embodiment distal end 40 is of a diameter less than the diameter of the elongate body 30 at the point distal end 40 joins to the body so as to create shoulders 30A and 30B. As will be appreciated by those skilled in the art, when the fastening means 10 is fixed to the second support member, shoulders 30A and 30B of the elongate body 30 will abut the planar face of second support means once the distal end 40 has entered completely into the second support member, thereby providing a maximum limit of insertion of elongate body 30 into the cavity between the first and second support members.

It will be further appreciated by those skilled in the art that the elongate body 30 and distal end 40 need not be unitary, which will allow for a mix of materials. For example the elongate body 30 might be formed of plastic, and the distal end 40 formed separately from a second rigid material (such as a metal screw or nail). In such embodiments the distal end 40 of the elongate body 30 would be formed with an opening large enough to admit the body of the screw or nail, but smaller than the head of the screw or nail so that the screw or nail remains retained within the elongate body 30 once fastened to an internal wall structure in the manner described below.

As will be apparent to those skilled in the art, in embodiments where the distal end 40 is in the form of a screw some means of rotation of the screw will be desirable to engage it with the underlying wall structure. Where the screw is a separate component and is passed through a hole in the proximate end 20 (as 11 James & Wells Ref: 233394/75 previously described), rotation may be achieved by inserting a suitable tool into the aperture to engage with the screw in known fashion. However, where the screw is integrally formed with the elongate body 30, some means of rotation of the entire fastening means 10 is required. This can be achieved by configuring the elongate body 30 so that it can receive a means of rotation, such as a spanner, screwdriver or the like.

In a preferred embodiment (not shown) proximate end 20 of elongate body 30 is formed with an aperture shaped so as to closely receive the head of a phillips head screw driver. Thus the entire fastening means 10 can be rotated following insertion of the screw driver head into the corresponding aperture in the proximate end 20 of the fastening means 10, thereby screwing the distal end 40 into the second support means until shoulders 30A and 30B abut the second support member. As the length of the elongate body 30 is adjustable typically by cutting (or snapping at weakened joins) that part of elongate body 30 containing the shaped aperture will usually by removed following adjustment providing a more aesthetically pleasing finish.

It will however be appreciated by those skilled in the art that other shapes and means of rotation might be effected. For example, the aperture in proximate end 20 might be formed into the shape of a hex to facilitate rotation via a hex (or alien) key. Alternatively, a shape corresponding to a means for rotation (such as a screw driver or hex key) might be formed within or at the bottom of an aperture which extends substantially the length of the elongate body 30.

In a further example, means for rotation may be effected on the outside of elongate body 30. For example elongate body 30 may be substantially cylindrical but hexagonal or square in shape at the proximate end 20, allowing it 12 James & Wells Ref: 233394/75 to be firmly gripped and rotated via a spanner, socket or gripping implement such as pliers. In this embodiment, the portion of the elongate body 30 that is shaped to assist rotation of the fastening means 10 may be removed when the length of the elongate body 30 is adjusted in the manner described earlier. Alternatively the entire length of elongate body 30 may be square or hexagonal etc in shape. Other variations will be apparent to those skilled in the art.

The proximate end 20 of the fastening means 10 is depicted in plan view in Figure 3. In the preferred embodiment the cylindrical elongate body 30 is formed from rigid plastic and is solid (i.e. it does not have an internal cavity). A marking 50 is located on the face of the proximate end 20 of the elongate body 30. This marking 50 indicates the entrance point for an attachment means such as a self tapping screw to be inserted into the plastic body 30. However it will be appreciated by those skilled in the art that alternative means of retaining an attachment means within elongate body 30 might be used. For example, an aperture might be formed within the elongate body 30 to receive a conventional attachment means such as a bolt. Alternatively, some form of adhesive (such as LOCTITE™) might be used to retain the attachment means within the aperture.

Similarly, in an alternative embodiment, the aperture may be sleeved with an additional insert that can be substituted to receive different types of secondary fixing. It is envisioned that the insert may be made of plastic, metal, wood or other material.

With reference to Figures 1 to 4, it can be seen that the proximate end 20 is the same circumference as the elongate body 30. This allows the proximate end 20 of the elongate body 30 to lie flush with or recessed from the outer wallboard once the fastening means 10 has been inserted into the wall in the manner 13 James & Wells Ref: 233394/75 described below. In this preferred embodiment the fastening means 10 can be easily painted over to make it less conspicuous.

Figure 5 and 6 show use of fastening means 10 to secure an object to a wall. Figure 5 shows the fastening means 10 prior to the elongate body 30 being adjusted in length. In use, fastening means 10 is inserted through a hole in wall board 60. The hole is made by drilling or boring through the wall board 60 in known fashion. Preferably the proximate end 20 of elongate body 30 is of substantially uniform diameter and the hole is sized to tightly receive the elongate body 30.

It is possible that in some applications the fastening means 10 will also pass through insulation space 70 which may be empty space, or filled with insulation materials such as polystyrene or fibreglass insulation. In situations where there is insulation in the insulation space 70, the pre-formed hole will preferably extend through both the wall board 60 and the insulation space 70 to make insertion of the fastening means 10 easier.

The distal end 40 of fastening means 10 is passed through the hole in wall board 60, where it is fixed to the solid frame of the wall 80. In the example shown in figures 5 and 6 wherein the distal end 40 is in the form of a tapered shaft, the fastening means 10 may be fixed into position by applying a force directly to the proximate end 20 of the fastening means 10, for example with a hammer. In alternative embodiments where the distal end 40 is in the form of a tapered screw, the fastening means may be rotated such that the distal end 40 becomes fixed within the wall 80. The method of insertion of the fastening means 10 into the wall 80 is not intended to be limited by these examples and it will be clear to 14 James & Wells Ref: 233394/75 a person skilled in the art what the most appropriate method for insertion of the fastening means 10 will be.

To further assist the fixing of the fastening means 10 to the wall 80, a second hole is preferably pre-formed in the wall 80 by drilling, puncturing or similar. Preferably the second hole formed in the wall 80 is dimensioned to tightly receive the distal fixing means 40. Insertion of the fastening means 10 by any of the methods described above will be assisted by having a pre-formed hole in the wall 80, particularly in situations where the wall 80 is formed from concrete, steel or other very rigid material.

As previously discussed the distal end 40 of the fastening means 10 has a significantly smaller diameter than that of the elongate body 30, creating shoulders 30A and 30B at the distal end 40 of the elongate body 30. In practice, the distal end 40 is inserted into wall 80 such that the shoulders 30A and 30Bof the elongate body 30 substantially abut the outer surface of the solid wall frame 80 providing a maximum level of insertion and ensuring the elongate body 30 spans the entire distance between support members once adjusted in the manner described below.

Once the fastening means 10 is in place within the walls 60 and 80, and the distal face 35 of the elongate body 30 abuts the outer surface of wall 80, the length of the elongate body 30 is adjusted to allow the proximate end 20 to lie flush against or recessed to the outer surface of the wall board 60. It is an essential feature of the invention that the elongate body 30 is substantially the same length as the distance between the outer surface of the wall board 60 and the surface of the solid frame 80 that is closest to the inner surface of wall board James & Wells Ref: 233394/75 60. Preferably the elongate body 30 is cut to the required length with a knife 52 or similar tool.

Figure 6 shows the preferred embodiment of the invention when used for securing an attachment to a wall.

As mentioned above, distal end 40 of fastening means 10 is inserted into the inner wall frame 80 via a pre-formed hole, until the proximate end 20 of the elongate body 30 lies flush with the outer surface of the wall board 60. An object 100 to be mounted onto the outer wall 60 (such as a curtain rail bracket) is attached via an attachment means (for example self tapping screw 90). In practice screw 90 is inserted through a corresponding hole in bracket 100 and then screwed into the solid plastic of the elongate body 30. The tightening of screw 90 clamps bracket 100 to the face of proximate end 20 thereby securing it tightly.

When a load is applied to a bracket 100 in the direction of the arrow A, it causes the elongate body 30 to bear down on the outer wall board 60 at area B, and the distal fixing means 40 to bear upwards on the inner solid wall frame at area C. The spreading of the load between the distal fixing means 40 and the elongate body 30 minimises the prospect of fastening means 10 moving within the wall board 60, providing a secure fastening means 10 that can support a load without pulling away from the wall 60.

A person skilled in the art may wish to use adhesives in conjunction with the distal fixing means to ensure a secure connection with the wall frame 80.

Aspects of the present invention have been described by way of example only and it should be appreciated that modifications and additions may be made 16 James & Wells Ref: 233394/75 thereto without departing from the scope thereof as defined in the appended claims. 17

Claims (16)

James & Wells Ref: 233394/75 WHAT I CLAIM IS:

1. A fastening means for securing an object to a plurality of support members, wherein at least a portion of the fastening means is inserted within a hole formed in a first support member, said fastening means comprising; • a distal end adapted for fastening to a second support member; characterised in that the length of the elongate body is capable of being reduced such that the combined length of the elongate body and exposed part of the distal end substantially corresponds to the distance between the outside face of the first support member and second support members; further characterised in that the largest diameter of the distal end of the fastening means is less than the diameter of the elongate body at the point at which the distal end joins to the elongate body; and the elongate body is substantially cylindrical.

2. The fastening means as claimed in claim 1 wherein the elongate body and distal end of the fastening means are integrally formed.

3. The fastening means as claimed in claims 1 or 2 wherein the fastening means is made from a rigid plastics material. an elongate body; a proximate end adapted to receive an attachment means; and 18 sglWtty offke I 3 JAN » James & Wells Ref: 233394/75

4. The fastening means as claimed in any one of claims 1 to 3 wherein the elongate body is configured with at least one weakened join.

5. The fastening means as claimed in any one of claims 1 to 4, wherein the elongate body contains an aperture adapted to receive an attachment means.

6. The fastening means as claimed in any one of claims 1 to 5 wherein the distal end of the fastening means is a tapered shaft.

7. The fastening means of claim 6 wherein the distal end of the fastening means is a tapered screw.

8. The fastening means of claim 7 wherein at least a portionof the elongate body is shaped to assist rotation of the fastening means.

9. The fastening means as claimed in any one of claims 1 -8 wherein at least a portion of the elongate body is shaped to receive a co-operating means of rotation.

10. The fastening means as claimed in claim 9 wherein the co-operating means of rotation is a screw-driver, spanner, socket, wrench or gripping implement.

11. The fastening means as claimed in claim 9 wherein the portion of the elongate body shaped to receive a co-operating means comprises an aperture in the proximate end of the elongate body.

12. A method for securing an object to a plurality of support members using the fastening means of claim 1, said method comprising: • inserting the distal end of a fastening means through a hole in a first support member; 19 James & Wells Ref: 233394/75 fixing the distal end of the fastening means into a hole in the second support member; adjusting the length of the elongate body such that the proximate end of the elongate body lies substantially planar to the outside face of the first support member; and fixing an object to the proximate end of the fastening means via an attachment means secured within the elongate body of the fastening means.

13. The method as claimed in claim 12 wherein the length of the elongate body is altered by cutting.

14. The method as claimed in claim 12 wherein the length of the elongate body is altered by severing the elongate body at weakened joins.

15. A fastening means as substantially described herein and with reference to the accompanying drawings.

16. A method of securing an object to a support member as substantially described herein and with reference to the accompanying drawings. 20