US20070235622A1

US20070235622A1 - Wallboard appurtenance attachment

Info

Publication number: US20070235622A1
Application number: US11/706,839
Authority: US
Inventors: Kerry Baran; Herbert Woiczyk
Original assignee: Individual
Current assignee: Individual
Priority date: 2006-02-14
Filing date: 2007-02-14
Publication date: 2007-10-11
Also published as: WO2007095351B1; WO2007095351A2; WO2007095351A3

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.

Description

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

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

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) ⅜, ½, ⅝, ¾, and 1 inch (25 mm) with ½ inch being the most commonly used.
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.
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 FIG. 1 b. 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.
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. 1 c, 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

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

FIG. 1 a is a cross-sectional depiction of a known prior art utilization of a nail in gypsum wallboard for supporting a weight.
FIG. 1 b is a cross-sectional depiction of a known prior art wallboard hanger.
FIG. 1 c is a cross-sectional depiction of a known prior art wallboard anchor utilizing an arcuate hook with the anchor inserted into gypsum wallboard.
FIG. 2 a is a cross-sectional view of an embodiment of the invention.
FIG. 2 b is a perspective view of the wall anchor and appurtenance of FIG. 2 a.
FIG. 3 a-d illustrate attachment of an embodiment of the invention to a wallboard.
FIG. 4 is a side view of a wall anchor with a flat on the upper surface of the prong.
FIG. 5 is a top plan view of the wall anchor of FIG. 4.
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.
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.
FIG. 8 a is a perspective view, an embodiment of the present invention in the form of a screw for anchoring large frame and shelving items.
FIG. 8 b is a perspective view of a threaded anchor prong and associated attachment hardware.
FIG. 9 a is a perspective view of an embodiment of the present invention in the form of a hanger suitable for use as a picture hanger.
FIG. 9 b is a perspective view of an embodiment of the present invention in the form of a hanger suitable for use as a picture hanger.
FIG. 9 c is a perspective view of opposite side of the hanger of FIG. 9 b.
FIG. 9 d is a perspective view of an embodiment of the present invention in the form of a hanger suitable for use as a picture hanger.
FIG. 9 e 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.
FIG. 9 d is a side elevational view of the hanger of FIG. 9 e.
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.
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.
FIG. 12 is a perspective view of a leaf anchor mounting plate which orients two leaves in opposition, secured by a single central screw.
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.
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.
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.
FIG. 16 is, in rear perspective view, an assembled picture frame using the double-sided tack embodiment of the present invention.
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.
FIG. 18 is, in rear perspective view, an assembled shelf using anchors of the preferred embodiment of the present invention.
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.
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.
FIG. 21 is, in side perspective view, an assembled toothbrush holder using anchors of the preferred embodiment of the present invention.
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.
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.
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.
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

Referring to FIGS. 2 a and 2 b 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.
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.
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.
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 FIG. 2 a, 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. 1 a and 1 c. Moreover slight loosening of the prong in the wallboard does not affect the integrity of the attachment as significantly as in the prior art.
Referring to FIGS. 3 a, 3 b, 3 c, and 3 d, 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. 9 b-9 d.
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. 3 a. 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. 3 b and 3 c. The appurtenance is lowered 90 degrees to the vertical upright position and where the wall engaging portion is flush with the wall; see FIG. 3 d. 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.
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.
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.
For heavier applications the wallboard anchor of the present invention may take the form of screw mount shank 25 as shown in FIG. 8 a. 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. 8 b 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.
In many applications, such as hanging picture frames or shelving on wallboard as shown in FIGS. 9 a-9 d 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. 2 a, 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.
Referring again to FIGS. 9 a-9 f, 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.
The invention includes methods of manufacturing wall anchors and methods of manufacturing appurtenances with integral or attached wall anchors. FIGS. 9 a-9 f 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. 9 a 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.
The embodiments as illustrated in FIGS. 9 b, 9 c, and 9 d 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. 9 e and 9 f 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.
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 FIG. 3 d, 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 ¼ no more than preferably ½ inch above the uppermost point of the wall engagement portion 9. A more preferable embodiment is where the uppermost point extends no more than ¼ inch above the uppermost point of the wall engagement portion 9. A most preferable embodiment is where the uppermost point extends no more than ⅛ inch above the uppermost point of the wall engagement portion 9.
Referring to FIG. 3 d, 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.
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.
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.
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. 8 a. 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.
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.
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.
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 ¼ rotation as illustrated by the extended point 39.1.
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.
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 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.
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.