WO1997000383A1

WO1997000383A1 - Cantilever fastener assembly

Info

Publication number: WO1997000383A1
Application number: PCT/US1996/011107
Authority: WO
Inventors: Salvatore J. Sisto; Edward A. Rudnicki
Original assignee: Sisto Salvatore J; Rudnicki Edward A
Priority date: 1995-06-19
Filing date: 1996-06-19
Publication date: 1997-01-03
Also published as: AU6481596A

Abstract

A fastener assembly (10) includes an elongated tubular body (12) having a face plate (14) at its proximal end. The tubular body (12) defines an axial cavity dimensioned to receive a support member. When inserted into a properly dimensioned hole formed in a support structure, for example a wall, the rear face of the face plate (14) contacts the portion of the support structure surface which surrounds the hole. The tubular body, and the support structure received therein, is maintained in position by an anchoring member (24) disposed proximate the distal end of the tubular body. The anchor member comprises a base portion (26) defining a central, threaded aperture (28). A plurality of elongated wings (30), bendable in the direction of the tubular body, extend from the base portion (26) in a direction toward the face plate (14). A threaded member (22), inserted into the threaded aperture (20), is rotated to draw the wings (30) into contact with the inside surface of the wall panel.

Description

CANTILEVER FASTENER ASSEMBLY BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to fasteners and in particular to

fasteners used to secure objects to structural assemblies such, for example, as walls defining either a hollow or solid core.

2. Description of the Background Art

Fasteners are typically installed in solid core walls or in hollow walls made of lightweight material, such as gypsum board, to attach objects to the wall. Such fasteners are useful in supporting relative heavy objects, such as framed pictures or shelves that are attached to the wall. According to prior practice, for example, fasteners installed in hollow walls are comprised of a threaded member, such as a bolt or screw, and an anchoring mechanism. Rotation of the threaded member causes the anchoring mechanism to expand and contact the inside of the wall to anchor the fastener in place. Common examples of such fasteners are the so-called "toggle" bolts and "moly" bolts. Various types of fasteners are described in the following U.S. Pat. Nos.: 4,136,599; 4,086,840; 4,077,300; 3,905,570; 3,874,264; 3,869,958; 3,752,032; 3,701,302; 3,605,846; 3,555,960; 3,534,797; 3,487,746; 3,366,405; 3,315,558; 3,211,044; 3,136,350; 3,104,582; and 1,978,935.

One problem associated prior art fasteners of the above type is that a portion of the anchoring mechanism is usually received within the hole in the wall through which the fastener is inserted. Therefore, stress exerted by heavy objects attached to the fastener on the outside of the wall may cause the fastener to pull outwardly through the opening. Another problem is that the fasteners must be carefully installed to insure that they are not over-torqued. Continued twisting of the threaded bolt or screw after the anchoring mechanism has contacted the inner surface of the wall will cause the anchoring mechanism to twist and dig into the inner surface of the wall. This

digging action gouges the periphery of the wall hole, which causes the fastener to fit

loosely within the wall and thereby increases the likelihood that the fastener will become dislodged from the wall.

Additionally, the supporting capacity /strength of conventional fastening structures is limited by a relatively short axis of rotation in the axial plane. As will be

readily appreciated by those skilled in the art, this axis is defined by the distance between the points of support provided by the anchoring assembly and threaded member. In the case of prior art configurations such, for example, as the "moly" bolt, this distance is equivalent to the thickness of the wall or wallboard and is typically far too short to support large or heavy objects due to the high concentration of stresses over such a small area.

There are, of course, other types of structural assemblies to which it would be desirable to secure relatively heavy objects. For example, aluminum frame members are commonly employed in the construction of store front window arrangements to provide the merchant with the largest possible display area for his or her wares.

Heretofore, however, the merchant wishing to display relatively heavy goods and other articles in the store window has been required to use large and expensive floor supported

displays since there has been no fastener available to take advantage of the supporting properties of the window frame members. It should also be noted that door mounting hardware such, for example, as hinges and self-closing mechanisms is typically secured to frame members of the abovementioned type. Repeated use of this hardware inevitably leads to failure due to the concentration of stresses about a relatively small area of attachment.

SUMMARY OF THE INVENTION

According to the present invention, the deficiencies associated with the

prior art are avoided by a fastener assembly which allows relatively heavy objects to be

attached to any structure capable of supporting the weight over a distributed area. The stresses exerted by such objects being distributed over a relatively wide area around, for example, a wall hole in which the fastener is inserted, and along a relatively long axial plane of support defined by an elongated cantilever structure. It is contemplated that the

fastener of the present invention may be employed in connection with the support of relatively heavy objects on such diverse structural assemblies as hollow and solid core walls, metal frame members, channels, and panel members, concrete and cinder block structures, as well as other structures which will become apparent to the artisan of ordinary skill.

An illustrative embodiment of the fastener assembly includes an elongated tubular body having a flange or face plate at its proximal end. The tubular body defines an axial cavity which may be dimensioned to receive a correspondingly dimensioned support member. When inserted into a properly dimensioned hole formed in a suitable support structure such, for example as a wall, ceiling, or floor, the rear face of the face plate contacts the portion of the support structure surface which surrounds the hole.

The elongated tubular body, as well as any support member received therein, is maintained in position by an anchoring member which, in accordance with one embodiment of the present invention, is disposed proximate the distal end of the tubular

body. The anchor member comprises a base portion defining a central, threaded aperture. A plurality of elongated wings extend from the base portion in a direction toward the face plate of the tubular body. The wings are bendable in the direction of the tubular body to allow the anchoring member to be inserted through the wall hole. The wings may be spring biased so that they expand outwardly from the tubular body, in the

case of a hollow wall, to engage the inner surface of the wall when the anchoring member

clears the hole on the inside of the wall. Alternatively, of course, provisions may be

made for mechanically manipulating the wings into the outwardly expanded configuration.

A threaded member such, for example, as a conventional screw or bolt, is insertable through the cavity of the elongated body and into the threaded aperture of the

anchoring member. As will be readily appreciated by those skilled in the art, as the screw is rotated, the anchoring member is drawn closer to the face plate of the tubular body until the edge surfaces of the anchoring member wings contact the inside surface of the wall (in the case of a hollow wall). The outside diameter of the face plate is preferably selected so that the wings of the anchoring member do not extend beyond the peripheral edge(s) thereof. This ensures that stresses are distributed only over those

portions of the surrounding wall which are in compression and thereby provides substantially enhanced mechanical strength and stability.

In accordance with a modified embodiment of the present invention, the anchor member is axially movable within the tubular body and maintained in a desired position relative thereto by, for example, a threaded screw that extends through a threaded aperture in the anchor member base portion and abuts against the end wall of the tubular body. Axial movement of the anchor member is accommodated by a pattern of slots radially arranged along the tubular body to permit complete extension of the wings regardless of the axial position relative to the tubular body face plate.

In accordance with a presently preferred embodiment of the present

invention, a compressible spacer element is inserted on the threaded member so as to be disposed between the base of the anchoring member and the distal end of the elongated tubular member. The length of the spacer element is preferably selected so as to establish

a minimum clearance between the tips of the elongated wings and the interior surface of

the wall panel while also providing initial, frictional engagement, at both ends, with the distal surface of the tubular body and the surface of the anchoring member base. This arrangement greatly simplifies installation by ensuring that the elongated wings may be brought into engagement with the interior surface of the wall panel once the threaded

member has been rotated a sufficient number of times. In the initial, partially compressed condition, the frictional engagement of the spacer element with the tubular body and anchoring member prevents rotation of the anchoring assembly as the threaded member is rotated.

The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of the disclosure. For

a better understanding of the invention, its operating advantages, and specific objects attained by its use, reference should be had to the accompanying drawings and descriptive matter in which there are illustrated and described several embodiments of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The features and advantages of the present invention will be more readily understood from the following detailed description when read in conjunction with the accompanying drawings, in which:

FIG. 1 is an exploded perspective view of a fastener assembly constructed in accordance with an illustrative embodiment of the present invention;

FIG. 2 is a cross sectional view depicting the interior construction of the tubular body member of the embodiment of FIG. 1;

FIG. 3 is a front elevation view showing the external appearance of the tubular body member of FIG. 2 as installed;

FIG. 4 is a side elevation view depicting the use of the fastener assembly of FIG. 1 on a hollow wall structure;

FIG. 5 is a side elevation view depicting the use of the fastener of FIG. 1 to secure a large rigid structural member to a target support structure;

FIG. 6 is a perspective view of a fastener assembly constructed in accordance with a modified embodiment of the present invention;

FIG. 7 is an exploded perspective view of a fastener assembly constructed in accordance with yet another embodiment of the present invention; and

FIG. 8 is a plan view of the fastener assembly of FIG. 7 installed with a metal stud of the type commonly employed in the construction of commercial office buildings and other structures. DETAILED DESCRIPTION OF THE INVENTION

In the description which follows, like parts are marked throughout the specification and drawings, respectively. The drawings are not necessarily to scale and in

some instances, proportions have been exaggerated in order to more clearly depict certain

features of the invention.

In any event, and with reference now to FIGS. 1-4, a fastener assembly 10 constructed in accordance with an illustrative embodiment of the present invention will

now be described in detail. Fastener assembly 10 includes an elongated tubular body 12 having a flange or face plate 14 at its proximal end. The tubular body 12 defines an axial cavity 16 (FIG. 2) which may be dimensioned to receive a correspondingly dimensioned support member (not shown). Of course, if it is not desired to utilize the fastener

assembly of the present invention to retain such a support member, a flush fitting cap or other closure member (not shown) dimensioned and textured to blend with face plate 14,

may be employed.

Although both the tubular body 12 and face plate 14 are shown as having a circular cross-sectional profile, it should be noted that such a configuration is for illustrative purposes only. It is, in fact, contemplated that a variety of cross sectional

profiles may be utilized, depending upon aesthetic considerations and the individual tastes of the user. Thus, for example, the face plate and/or tubular body may have an oval or semicircular (arched) profile, or a polygonal (e.g., triangular, trapezoidal, hexagonal, octagonal, etc.) cross sectional profile.

Tubular body 12 further includes a distal end wall 18 having a centrally located aperture dimensioned to receive threaded member 22 (FIGS. 2 and 3). When

tubular body 12 is inserted into a properly dimensioned hole formed in a suitable support structure such, for example as a wall, ceiling, or floor, the rear face of the face plate contacts the portion of the support structure surface which surrounds the hole.

The elongated tubular body 12, as well as the support member received

therein, is maintained in the position shown in FIG. 4 by an anchoring member 24 which

is disposed proximate the distal end of the tubular body 12. The anchoring member 24

comprises a base portion 26 that defines a central aperture correspondingly threaded to receive threaded member 22. A plurality of elongated wings 30 extend from the base portion 26 in a direction toward the face plate 14 of tubular body 12. Optionally, the wings 30 may be bendable in the direction of the tubular body to allow the anchoring member 24 to be inserted through a wall hole. In the embodiment of FIG. 4, the wings 30 are also spring biased so that they expand outwardly from the tubular body, in the case of a hollow wall, to engage the inner surface of the wall when the anchoring member clears the hole on the inside surface of wall panel W. It should be noted, however, that spring biasing of the wings is not required in that other techniques for expanding the wings, upon insertion into a structural assembly or member, may be employed.

It will be readily appreciated by those skilled in the art that in forming a hole through which the tubular body will be inserted, additional clearance must be provided for the contracted wings. With particular reference to FIG. 4, it will be seen that a spacer 25 may be employed to ensure a suitably tight fit of the tubular body within the thus configured hole.

Threaded member 22, which may be, for example, a conventional screw or bolt, is inserted through the cavity 16 of the elongated body and into the threaded aperture 28 of anchoring member 24. As will be readily appreciated by those skilled in

the art, as threaded member 22 is rotated, the anchoring member 24 is drawn closer to face plate 14 until the edge surfaces 30a of anchoring member wings 30 contact the inside surface of the wall (as shown in FIG. 4). In this regard, it will be noted that an

adhesive layer 23 (FIG. 2) may be applied or otherwise provided on the rear surface of

flange 14 to restrict rotation of the tubular member during installation and to enhance the reliability of the structure thereafter.

In the absence of a strong structural member interposed between face plate 14 and wings 30 of anchoring member 24, the outside diameter of face plate 14 is preferably selected so that the biased wings 30 of the anchoring member 24 do not extend

beyond the peripheral edge(s) thereof. This arrangement ensures that stresses are

distributed only over those portions of the surrounding wall which are in compression and thereby provides substantially enhanced mechanical strength and stability. Where the fastener of the present invention is employed to secure a large, structurally rigid member as member 27 to a wall, such as in the installation depicted in FIG. 5, the wings may extend beyond face plate 14. Indeed, the structurally rigid member 27 may itself be considered an extension of the face plate 14 in that the two components together serve to distribute forces over a much greater area than face plate 14 alone. Thus, for example, the fastener of the present invention may be employed to secure a kitchen cabinet or

similar structure to a gypsum board wall structure.

Returning to FIG. 4, it will be observed that a compressible spacer element 32 is inserted on the threaded member so as to be disposed between the base 26 of anchoring member 24 and the distal end 18 of tubular body 12. The length of the spacer element is preferably selected so as to establish a minimum clearance between the tips 30a of the elongated wings 30 and the interior surface of wall panel W while also providing initial, frictional engagement, at both ends, with the distal surface of the tubular body and the surface of the anchoring member base. This arrangement greatly simplifies

installation by ensuring that the elongated wings may be brought into engagement with the

interior surface of the wall panel once the threaded member has been rotated a sufficient number of times. In the initial, partially compressed condition, the frictional engagement

of the spacer element with the tubular body and anchoring member prevents rotation of

the anchoring assembly as the threaded member is rotated. The compressible spacer element may be fabricated from any resilient material having a sufficient coefficient of friction, when partially or uncompressed, to minimize relative movement between the tubular body and anchoring member during installation.

With reference now to FIG. 6, it will be seen that other configurations of

the fastener assembly of the present invention are possible. In the embodiment of FIG. 6, the anchor member 124 is dimensioned for axial movement within tubular body 112. The anchor member 124 is maintained in a desired position relative to the tubular body 112 by a threaded screw 122 that extends through a threaded aperture 128 in the base portion 126 of anchor member 124 and abuts against tubular body end wall 118. Axial movement of the anchor member is accommodated by a pattern of slots 129 radially arranged along the tubular body and dimensioned to permit complete extension of wings 130 regardless of the axial position relative to the tubular body face plate.

With reference to FIGS. 7 and 8, there is shown an embodiment of the fastener of present invention modified for use in conjunction with rigid structural members such, for example, as steel studs or exterior sheathing panels. As seen in FIG. 7, tubular body 212 is modified such that one or more elongated projections 213 extend from the lower exterior portion of rear end wall 218. By way of illustrative example, these projections may be configured as pins, with either flat or rounded tips, or as teeth configured to bite into the surface of a stud or panel. For a purpose which will soon be explained, the anchoring member 224 is also modified in that the wings 230 are

distributed to define a gap region to accommodate projections 213. Turning to FIG. 8, it

will be seen that when the fastener 210 is inserted through an opening in one flange portion of stud S, projections 213 engage into the other flange portion. This arrangement

advantageously exploits the structural strength of the stud while also providing additional cantilever support utilizing the wing structure of the present invention.

In accordance with a further embodiment of the present invention modified for use in conjunction with rigid structural members, not shown, the anchoring member is omitted altogether. The tubular body is modified such that one or more elongated projections extend from both the upper and lower exterior surface portions of the tubular body rear end wall. Here again, these projections may be configured as pins, with either flat or rounded tips, or as teeth configured to bite into the surface of a stud or panel. To

ensure stability in the case of horizontally directed loads, such as those caused by a strong wind upon the surface of a sign, additional elongated projections are preferably included at intermediate exterior portions of the tubular body end wall.

Fastener assemblies constructed in accordance with the present invention can carry a wide variety of attachments and assume a myriad of configurations. For instance, the fastener could be employed as an integral wall anchor to secure a cabinet to a hollow wall or function as a separate fastener in place of screws, nails, or rivets. Similarly, tubular body 12 could carry shelving brackets or define attachment means for

detachable brackets as commonly used in shelving systems. In this regard, the elongated stem of an object to be supported, or of an underlying support member, may be merely

inserted into the axial cavity of tubular body 12. To further enhance the reliability of the support arrangement, means may be included to selectively lock the inserted stem within

the cavity of the tubular body. In the case of a tubular body having a circular cross- sectional profile, for example, the exterior surface of the stem and interior surface of the

tubular body may be threaded for mating engagement with the object supporting stem being inserted by rotating the same until it is fully inserted into the tubular body.

It will be readily appreciated by those skilled in the art that other interlocking arrangements may also be employed. Thus, by way of further example, a flange or mounting collar secured to the object supporting stem may be provided with appropriate apertures and attached to the face plate 14 by threaded screws, an adhesive

compound, or other suitable means. By way of yet another example, the object stem and axial cavity may be configured with inter-engaging serrations to impede axial movement of the installed object step. Alternatively, the object supporting stem and axial cavity may be provided with a conventional twist-and-lock arrangement using, for example, an interference fit (friction-lock). By way of example, assuming an axial cavity having an ellipsoidal cross-sectional profile, the object supporting stem may be configured with an ellipsoidal cross sectional profile extending at least a portion of its length and having a major axis which is slightly larger than the minor axis of the axial cavity but sufficiently smaller than the major axis of the axial cavity to permit the stem to be inserted when the axes of each are aligned. As will be readily ascertained by those skilled in the art, once the object supporting stem has been successfully introduced into the axial cavity, the former may be rotated until a frictional lock is achieved.

In view of the foregoing illustrative examples, it should now be readily apparent that a variety of interlocking configurations may be achieved to ensure stable retention of an elongated object supporting stem in accordance with the present invention. Moreover, the configuration of the tubular body itself may be modified in a variety of ways. It will be readily appreciated by those skilled in the art that the overall function of

the tubular body is to supply (1) a face plate suitable for engagement with the mounting

surface and (2) a support surface positionable within the interior of the mounting structure and spaced from the face plate to guide movement of the anchor member. Accordingly,

any structure which provides this functionality will suffice for the purposes of the present invention. By way of illustrative example, it is contemplated that even an arrangement of

two parallel plates, one dimensioned for use as the face plate and one as the end wall,

may be secured together by a plurality of elongated threaded members or other mechanical means to provide a structure capable of supporting and guiding the anchor member.

While the above embodiments and written description are directed towards an anchor or an attachment means suitable for hollow or easily traversed walls or

ceilings, the present invention is equally suitable for use within a solid structure such as brick, concrete, or wood. For solid structures, a pilot hole is provided which permits the snug insertion of the wings and base of the anchoring member. Upon engagement with the distal end of the tubular body or, if applicable, the spacer, the wings of the anchoring

member are expanded within and against the pilot hole. Depending upon the nature of the solid material, the wings may partially spread in certain types of soft wood or compressed wood products or where a slightly oversized pilot hole is provided. Where the material or pilot hole size does not permit expansion, the wings will deform. In either case, an extremely tight and secure frictional fit is obtained between the anchor and the solid material. A suitable adhesive may be used to further enhance the

interconnection. It will be readily appreciated by those skilled in the art that the fastener

assembly of the present invention may be fabricated from any material having sufficient shear strength to withstand reasonable weights and loads placed upon the tubular body and any attachments. In addition, the wing material should be flexible to permit the necessary projection or flaring of the wings. Material such as nylon or plastic has been found to

permit a unitary apparatus having the desired combination of desirable properties including strength, moldability and flexibility. While the preferred embodiments of the present invention are of plastic or rigid nylon, any moldable material including graphite,

fiberglass, or polyethylene will suffice. An equivalent structure can be provided from

other materials such, for example, as metal or wood, or alloys/composites thereof.

Claims

What is claimed is:

1. A fastener assembly for fastening objects to a supporting structure,

comprising:

a tubular body having a main body portion and a face plate at a proximal end of the main body portion having a greater outer cross sectional profile than said main body portion, said tubular body defining an axial cavity and an end wall at a distal end thereof;

an anchoring assembly having a base portion positionable proximate said apertured end wall and a plurality of wing members extending axially from said base portion, wherein one of the tubular body end wall and anchoring assembly base portion defines a threaded aperture; and a threaded member dimensioned for insertion into the axial cavity of said tubular body and into said threaded aperture whereby rotation of said threaded member causes axial movement of said anchoring assembly relative to said tubular body.

2. The fastener assembly of claim 1, further including a cantilever support member dimensioned for insertion into said axial cavity and for frictional engagement

with an interior surface portion thereof.

3. The fastener assembly of claim 1, wherein said wing members are resiliently biased.

4. The fastener assembly of claim 1, wherein said tubular body distal end wall defines a first, unthreaded aperture and said anchoring member base portion defines a second, threaded aperture, said fastener assembly further comprising a compressible spacer having an axial bore dimensioned to receive said threaded member, said spacer being positionable in contact between the distal end wall of the tubular body and the

anchoring assembly and having a length selected such that when compressed, forward edge surfaces of said wings engage interior surface portions of the supporting structure.

5. The fastener assembly of claim 4, wherein said spacer is comprised of a resilient material.

6. The fastener assembly of claim 1, wherein said anchoring assembly and said tubular body are comprised of a molded plastic material.

7. The fastener assembly of claim 1, wherein the axial cavity of said tubular body has a circular cross sectional contour.

8. The fastener assembly of claim 1, further comprising an adhesive layer secured to a rear surface portion of said face plate.

9. The fastener assembly of claim 1, wherein said anchoring member base portion defines said threaded aperture, and wherein said tubular body defines a plurality of radially arranged longitudinal slots corresponding in number to said wing members, the

base portion of said anchoring assembly being axially movable between said face plate and said tubular body end wall upon rotation of the threaded member. a holder structure having a proximal face plate portion and a distal end wall

portion;

an anchoring assembly having a base portion positionable proximate said

distal end wall portion and a plurality of wing members extending axially from said base portion, wherein at least one of said holder structure distal end wall portion and said anchoring assembly base portion defines an aperture; and

a positioner for axially moving the base portion of said anchoring assembly relative to said distal end wall portion, whereby said wing members may be moved into engagement with an interior surface of the support structure to thereby place a section of the support structure in compression against said proximal face plate portion.

11. The fastener assembly of claim 10, wherein said holder structure comprises a tubular body having a main body portion defining an axial cavity

dimensioned to receive an elongated support member, said proximal face plate portion and said distal end portion being disposed at opposite ends of said tubular body.

12. The fastener assembly of claim 10, further including a spacer element having a central aperture dimensioned and arranged to conform to an outer cross sectional profile of said tubular body proximate the face plate portion, whereby a tight-fitting

engagement of said tubular body within an aperture formed in the support structure may be obtained.

13. The fastener assembly of claim 10, wherein said distal end wall portion comprises a plate member interconnected to said face plate portion by a plurality of threaded members and arranged substantially parallel thereto. 14. The fastener assembly of claim 10, further comprising an adhesive layer secured to a rear surface of said proximal face plate portion.

15. The fastener assembly of claim 10, wherein said positioner comprises a threaded member insertable through a correspondingly threaded opening in the base portion of the anchoring assembly.

16. The fastener assembly of claim 15, wherein the base portion of said anchoring assembly is axially movable between said face plate portion and said distal end wall portion upon rotation of said threaded member.

17. The fastener assembly of claim 15, wherein the threaded member is further insertable through an aperture in said distal end wall portion.

18. The fastener assembly of claim 10, wherein said positioner is operative to move the base portion of said anchoring assembly axially between said face plate portion and said distal end wall portion.

19. The fastener assembly of claim 10, wherein at least a lower surface portion of said distal end wall defines at least one elongated projection engageable with an opposed interior surface of the support structure. 20. A fastener assembly for fastening objects to a rigid supporting structure, comprising: a tubular body having a main body portion and a face plate at a proximal

end of the main body portion having a greater outer cross sectional profile than said main body portion, said tubular body defining an axial cavity for retaining a support member in a cantilevered manner and having an end wall at a distal end of said main body portion; wherein an exterior surface portion of said end wall defines a plurality of

elongated projections engageable with opposed interior surface portions of the support structure.