WO2007013067A2

WO2007013067A2 - Drywall hanging devices and corresponding methods

Info

Publication number: WO2007013067A2
Application number: PCT/IL2006/000859
Authority: WO
Inventors: Gilad Rafaeli
Original assignee: M.G.H. Agricultural Cooperative Society Ltd.
Priority date: 2005-07-25
Filing date: 2006-07-25
Publication date: 2007-02-01
Also published as: WO2007013067A3

Abstract

A device for hanging an object on a drywall structure has a surface attachment arrangement including a substantially planar surface, and a quantity of adhesive deployed on the surface for attachment to a surface of the drywall structure. A mechanical linkage interconnets the surface attachment arrangement with an element which penetrates into the drywall structure so as to oppose withdrawal of the penetration element from the drywall structure. In a first set of embodiment set of embodiments, the mechnical linkage is achieved by forming the penetration element as a nib integrally with part of the surface attachment arrangement. In an alternative set of embodiments, the mechanical linkage is achieved by providing a locking configuration which tends to retain a penetration elements such as a nail inserted therethrough.

Description

DRYWALL HANGING DEVICES AND CORRESPONDING

METHODS

FIELD AND BACKGROUND OF THE INVENTION

The present invention relates to devices for hanging objects on walls and, in particular, it concerns devices suitable for hanging articles on drywall structures and corresponding methods.

It is common to form various parts of building structures using drywall panels, namely, panels formed by gypsum sandwiched between two pieces of heavy paper, alternatively referred to as SHEETROCK^®, plasterboard, wallboard, GWB, or GYPROC^®. Hanging objects on drywall panels is problematic because the material is easily torn and not smooth. If a nail is driven directly into the substrate, the substrate tends to crumble where compressed by the nail, and fails to grip the nail sufficiently to fix it into the substrate. If a self-adhesive pad attached to a hook, for example, is attached to the substrate, it can hold only a small amount of weight before detaching from the substrate together with a portion of the surface. This problem has resulted in development of butterfly anchors or devices consisting of multiple headless pins attached to a hook which tend to damage the back side of the drywall substrate. Alternatively, many users prefer to avoid the problem by nailing only in areas that are backed by beams.

There is therefore a need for simple and effective devices suitable for hanging objects on drywall structures, and for corresponding methods.

i SUMMARY OF THE INVENTION

The present invention provides various simple and effective devices suitable for hanging objects on drywall structures, and corresponding methods of hanging objects on a drywall structure. In a generic sense, most embodiments of the present invention include: a surface attachment arrangement having a substantially planar surface and a quantity of adhesive deployed on the surface for attachment to a surface of the drywall structure; a penetration element configured for penetrating into the drywall structure; and a mechanical linkage interconnecting between the surface attachment arrangement and the penetration element. The mechanical linkage is such that, when the device is deployed with the penetration element penetrating into the drywall structure and the surface attachment arrangement attached to the surface of the drywall structure, attachment of the surface attachment arrangement opposes withdrawal of the penetration element from the drywall structure. In a first subset of embodiments, the mechanical linkage is achieved through integral formation of the substantially planar surface and the penetration element. In a second subset of embodiments, the penetration element -is a nail, and the mechanical linkage is achieved by configuring the attachment arrangement to deform and create a locking configuration which opposes withdrawal of the nail from the drywall structure.

In an aspect of an embodiment of the present invention, a drywall hanging device includes a disk with a pointed nib extending from one side of the disk, on this side the disk being covered with a self-adhesive pad, and a hook-like protrusion extending from the other side of the disk.

In a further aspect of an embodiment of the present invention, a drywall hanging device includes a hard flexible layer attached to a foam-like self- adhesive pad which is adhered to a drywall substrate. When a nail is driven through the pad, the material making up the hard flexible layer bends in around the nail, locking the nail into the hole.

In a further aspect of an embodiment of the present invention, a drywall hanging device includes a disk with a pointed nib extending from one side of the disk, on this side the disk being covered with a self-adhesive pad, and a hook-like protrusion extending from the other side of the disk.

Thus, according to the teachings of the present invention there is provided, a device for hanging an object on a drywall structure, the device comprising: (a) a first layer of compressible material having a first surface and a second surface; (b) adhesive deployed on the first surface for attaching the device to the drywall structure; and (c) a second layer of flexible, substantially non-compressible material bonded to the second surface of the first layer, the first and second layers being configured such that, when a penetrating element penetrates through the second and first layers, the second layer deforms locally so as to form a locking formation opposing withdrawal of the penetrating element.

According to a further feature of the present invention, the first layer has a thickness of at least about 0.5 millimeter. According to a further feature of the present invention, the second layer has a thickness of at least about 0.4 millimeter.

According to a further feature of the present invention, the first layer is formed from foam-like material. According to a further feature of the present invention, the second layer is formed from plastic.

According to a further feature of the present invention, the adhesive is applied substantially continuously over the first surface of the first layer, the device further comprising a peel-off covering for covering the adhesive prior to use.

According to a further feature of the present invention, there is also provided a penetrating element penetrating through the second and first layers.

According to a further feature of the present invention, the first and second layers are bonded by an additional layer of adhesive. There is also provided according to the teachings of the present invention, a method for hanging an object from a drywall structure, the method comprising: (a) attaching to the drywall structure a hanging device including: (i) a first layer of compressible material having a first surface for attachment to the drywall structure and a second surface, and (ii) a second layer of flexible, substantially non-compressible material bonded to the second surface; and (b) driving a penetrating element through the second and first layers so that the second layer deforms locally to form a locking formation opposing withdrawal of the penetrating element. There is also provided according to the teachings of the present invention, a device for hanging an object on a drywall structure, the device comprising: (a) an integrally formed block including: (i) a nib for penetrating into the drywall structure, and (ii) a flange at least partly circumscribing a base of the nib, the flange presenting a substantially flat attachment surface; (b) an adhesive configuration bonded to the attachment surface and configured to attach the flange to a surface of the drywall structure; and (c) a hanging configuration attached to or integrally formed with the block, the hanging configuration being configured for supporting an object. According to a further feature of the present invention, the block is integrally formed from plastic.

According to a further feature of the present invention, the nib is rotationally symmetric about a longitudinal axis.

According to a further feature of the present invention, a major part of the nib is substantially cylindrical.

According to a further feature of the present invention, the nib is substantially conical.

According to a further feature of the present invention, the nib has an extensional direction perpendicular to the attachment surface. According to a further feature of the present invention, the flange completely circumscribes the nib. According to a further feature of the present invention, at least one dimension of the flange is greater than a length of the nib projecting from the flange.

According to a further feature of the present invention, the adhesive configuration includes: (a) a layer of resilient material having a first face bonded to the attachment surface, and (b) adhesive deployed on a second face of the layer for attaching the flange to the surface of the drywall structure.

According to a further feature of the present invention, there is also provided a peel-off covering for covering the adhesive prior to use. According to a further feature of the present invention, the first face is bonded to the attachment surface by adhesive.

According to a further feature of the present invention, the adhesive configuration is implemented as a quantity of adhesive deployed directly on the attachment surface. According to a further feature of the present invention, the hanging configuration is integrally formed with the block.

According to a further feature of the present invention, the hanging configuration includes a hook.

According to a further feature of the present invention, the hanging configuration includes a rotationally symmetric wire-retention configuration.

According to a further feature of the present invention, the block is rotationally symmetric. BRIEF DESCRIPTION OF THE DRAWINGS

Exemplary non-limiting embodiments of the invention are described in the following description, read with reference to the figures attached hereto. In the figures, identical and similar structures, elements or parts thereof that appear in more than one figure are generally labeled with the same or similar references in the figures in which they appear. Dimensions of components and features shown in the figures are chosen primarily for convenience and clarity of presentation and are not necessarily to scale. The attached figures are:

FIG. IA is a schematic cross-sectional view of a first embodiment of a drywall hanging device, constructed and operative according to the teachings of the present invention;

FIGS. IB and 1C are front and rear isometric views, respectively, of the drywall hanging device of Figure IA;

FIG. 2A is a schematic cross-sectional view of a second embodiment of a drywall hanging device, constructed and operative according to the teachings of the present invention;

FIGS. 2B and 2C are front and rear isometric views, respectively, of the drywall hanging device of Figure 2 A;

FIG. 3 is a schematic cross-sectional view of a third embodiment of a drywall hanging device, constructed and operative according to the teachings of the present invention. DESCRIPTION OF TBDB PREFERRED EMBODIMENTS

The present invention provides various simple and effective devices suitable for hanging objects on drywall structures, and corresponding methods of hanging obj ects . The principles and operation of devices and methods according to the present invention may be better understood with reference to the drawings and the accompanying description.

By way of introduction, it should be noted that the various embodiments of the present invention are based upon a common fundamental concept, namely, that effective support for hanging an object on a drywall structure can be achieved by anchoring a penetration element (a nail or the like) against withdrawal or other small displacements by mechanically linking the penetration element to a surface attachment arrangement adhered to the drywall structure's surface. In a first set of embodiments, illustrated below with reference to Figures 1A-2C, the mechanical linkage is achieved by forming the penetration element as a nib integrally with part of the surface attachment arrangement. In an alternative set of embodiments, illustrated below with reference to Figure 3, the mechanical linkage is achieved by providing a locking configuration which tends to retain a penetration element such as a nail inserted therethrough.

Turning now to the first set of embodiments, these are illustrated particularly with reference to Figures IA- 1C and 2A-2C. In each case, there is shown a device, generally designated 100 for hanging an object (not shown) on a drywall structure 140. Generally speaking, device 100 includes an integrally formed block 105 including a nib 110 for penetrating into drywall structure 140, and a flange 115 at least partly circumscribing a base of the nib. Flange 115 presents a substantially flat attachment surface 125. Bonded to attachment surface 125 is an adhesive configuration 135, configured to attach flange 115 to the surface of drywall structure 140. Device 100 also includes a hanging configuration 130, attached to or integrally formed with block 105, configured for supporting an object.

Nib 110 may be any pin or other projecting configuration effective to anchor itself into the body of the drywall structure. In the non-limiting preferred cases illustrated here, nib 110 is rotationally symmetric about its central longitudinal axis. In a first preferred set of implementations, nib 110 is primarily cylindrical, as illustrated in Figure IA- 1C. Optionally, as also illustrated here, nib 110 may be formed with an additional tapered penetrating point to facilitate penetration of the device into the drywall structure without prior preparation of a hole. Alternatively, a blunt-ended cylinder may be used. In the latter case, nib 110 is typically inserted into a hole formed in a separate preparatory step using a nail or other hole-making tool. In a further set of implementations, nib 110 is substantially conical as illustrated in Figures 2A- 2C, typically converging at an angle of a few degrees. Optionally, in order to avoid an overly sharp and frangible tip, the conical form may be truncated as shown. Most preferably, although not necessarily, an extensional direction of nib 110 in each of the embodiments is perpendicular to attachment surface 125. Turning now to flange 115, in the preferred examples illustrated here, flange 115 completely circumscribes nib 110. The maximum dimension, typically height or diameter, of flange 115 is preferably greater than, and most preferably at least twice, a length of nib 110 as measured from attachment surface 125. In certain cases, however, it should be noted that a long nib extending beyond the thickness of the drywall board material may be used. Particularly in such cases, the aforementioned ratios of dimensions may no longer be preferred.

Turning now to adhesive configuration 135, this most preferably includes a layer 120 of resilient material having a first face bonded to attachment surface 125, and adhesive 145 deployed on a second face of layer

120 for attaching flange 115 to the surface of drywall structure 140. Preferably, a peel-off covering (not shown) is provided for covering adhesive 145 prior to use. Bonding of layer 120 to attachment surface 125 is preferably also achieved by application of an adhesive 155, which may be similar to, or differ from, adhesive 145. Other attachment techniques, such as thermal bonding or layer

120 to attachment surface 125, may also be used.

Although the use of layer 120 is believed advantageous, it should be noted that adhesive configuration 135 may alternatively be implemented as a quantity of adhesive deployed directly on attachment surface 125.

Hanging configuration 130 may be implemented as any configuration . effective for hanging an object. Examples include, but are not limited to, hooks as will be exemplified in Figures IA- 1C and rotationally symmetric wire- retention configurations as will be exemplified in Figures 2A-2C.

Turning now specifically to Figures IA- 1C, these are schematic views of a drywall hanging device 100 in accordance with an embodiment of the present invention. In this exemplary embodiment, a pointed nib 110 extends from one side of a disk (or flange) 115. Resilient layer 120 is implemented as a rigid foam-like pad 120 covered with glue on two sides and adhered to the nib- side of the disk. The side of the pad not adhered to the disk is covered with a peel-off paper covering (not shown) for convenient handling prior to use. A hook-like projection 130 extends from the opposite side of the embodiment.

Prior to use, the paper covering 121 is removed from the pad 120. The nib of the device is then placed against the substrate 140, and a driver (not shown), for example a hammer, is lightly impacted on the hook-side of the device, driving the pointed nib 110 into the substrate 140 until pad 120 is pressed against the surface of the substrate, causing the glue on the pad 120 to adhere to the substrate and locking the nib into the substrate. An object is hung from the hook 130.

Turning now specifically to Figures 2A-2C, these show an alternative embodiment with equivalent functioning features labeled similarly. The hook- like protrusion is here shaped as a circle and recessed from the body of the device, forming a mushroom-like wire retaining configuration, to facilitate hanging a wire from the device. A wide range of other shapes and forms are possible, as will be clear to one ordinarily skilled in the art. The foam-like self- adhesive pad may be replaced with a thick layer of glue. This and other embodiments of the device may be formed from plastic, wood, metal, or any other material or combination of materials. For reasons of production efficiency and economy, it is considered particularly advantageous to implement the entirety of block 105, preferably including hanging configuration (hook) 130, integrally formed from plastic, such as by injection molding. In the example of Figures 2A-2C, the entirety of block 10 and wire suspension configuration 130 is rotationally symmetric, thereby rendering it insensitive to the orientation at which it is attached to a wall. It has been found that the combination of features described herein is effective to support loads significantly greater than can be supported by either adhesive pads or nails alone. Without in any way limiting the scope of the invention, this is believed to be the result of a unique synergy between the "nib" and the adhesive pad of the present invention. Specifically, the adhesive overcomes the primary problem of using a nail-type retaining element in drywall structures, namely, that it tends to slip out or otherwise shift during application of a load thereto, thereby compromising the internal mechanical structure of the drywall. At the same time, the penetration of the nib into the drywall provides mechanical anchoring of the device to support loads much greater than could be supported by superficial adhesion of an adhesive pad alone.

Preferred non-limiting examples of dimensions for round pads would be diameters in the range from 15 mm to 50 mm, and for rectangular pads, typical dimensions would be rectangles of dimensions from about 15 mm x 20 mm to about 40 mm x 80 mm. Preferred non-limiting examples of dimensions for the nib would be up to 12mm length and a diameter of up to about 5 mm. The pad may also be positioned asymmetrically relative to the nib. Optionally, a hole may first be made in the substrate using a nail guide such as described in PCT patent application publication no. WO 2005/072063 or by other means, thereby reducing the force required for insertion of the nib into the substrate.

Turning now to the second set of embodiments of the present invention, illustrated with reference to Figure 3, these provide a device, generally designated 200, for hanging an object (not shown) on a drywall structure 260. Generally speaking, device 200 includes a first layer 230 of compressible material, adhesive 240 deployed on a first surface of layer 230 for attaching device 200 to drywall structure 260, and a second layer 220 of flexible, substantially non-compressible material bonded to a second surface of first layer 230. First and second layers 230 and 220 are configured such that, when a penetrating element such as a nail 270 penetrates through layers 220 and 230, second layer 220 deforms locally so as to form a locking formation 225 opposing withdrawal of nail 270.

In certain preferred implementations, first layer 230 is formed from foam-like material, and second layer 220 is formed from plastic. Bonding of first and second layers 230 and 220 may be achieved by use of an adhesive layer 245, thermal bonding (lamination) techniques, or any other suitable bonding technique, as will be clear to one ordinarily skilled in the art. Advantageously, adhesive 240 is applied substantially continuously over the first surface of first layer 230, and a peel-off covering (not shown) is provided for covering the adhesive prior to use. In certain preferred implementations, first layer 230 and two layers of adhesive 240, 245 may be implemented as commercially available double-sided adhesive strip or sheet material.

Thus, in summary, Figure 3 shows an exemplary embodiment of drywall hanging device 200 in which a hard flexible layer 220 is attached to a foam-like pad 230, which is covered in glue 240 on one side. The glue is covered with a peel-off paper covering 250 (not shown). Penetrating element 270 may be any type sharp elongated element capable of being driven into the drywall structure and supporting a load. Examples of penetrating elements include all types of nails, pins, tacks and staples, and in some cases, screws. Penetrating element 270 may be formed from metal, hard plastic or any other suitable material. Prior to use, the paper covering 250 is removed from the foam-like pad

230. Then, according to the method of the present invention, the glue-side of the pad is then placed against the substrate 260, causing the pad 230 to adhere to the substrate 260. A penetrating element, such as nail 270, is driven through the pad 200 into the substrate 260 by a driver (not shown), for example a hammer, causing the material making up the flexible layer 220 to deform locally, bending in around the nail, thereby forming a locking formation 225 which locks nail 270 into the hole formed in the substrate 260, opposing withdrawal of the nail. An object (not shown) is hung from the nail 270. It has been found that the combination of features described herein is effective to support loads significantly greater than can be supported by a similar nail without the pad of the present invention. Without in any way limiting the scope of the invention, this is believed to be the result of the locking effect of the flexible layer of the adhesive pad of the present invention. Specifically, the pad overcomes the primary problem of using a nail-type retaining element in drywall, namely, that it tends to slip out or otherwise shift during application of a load thereto, thereby compromising the internal mechanical structure of the drywall. By locking the nail in place, the present invention allows the nail to transfer forces to the drywall without damaging motion and without slipping out of place.

In a different embodiment of the device, the foam-like pad 230 could require the application of glue. In a different embodiment of the device glue could be applied directly to the flexible layer 220, eliminating the foam-like pad. The driver could drive a screw, rivet, or other such component. The pad 200 could be in the form of a circle, rectangle, square, or any other shape.

Some non-limiting preferred examples of materials for the flexible layer 220 are plastic, rubber, or other flexible material. A thin layer of plastic material, such as polyvinyl chloride (PVC), is believed to be particularly effective. Some non-limiting preferred examples of thicknesses for the flexible layer 220 start from about 0.4 mm and are preferably no more than about 2.5 mm. A non-limiting preferred example of material for the foam-like layer 230 is polyethylene or other flexible material. Some non-limiting preferred examples of thickness for the foam-like layer 230 are at least about 0.5 mm, and typically in the range of 1-1.5 mm.

The present invention has been described using non-limiting detailed descriptions of embodiments thereof that are provided by way of example and are not intended to limit the scope of the invention. It should be understood that features and/or steps described with respect to one embodiment may be used with other embodiments and that not all embodiments of the invention have all of the features and/or steps shown in a particular figure or described with respect to one of the embodiments. Variations of embodiments described will occur to persons of the art.

Furthermore, the terms "include", "comprise", "have" and their conjugates, shall mean, when used in the disclosure and/or claims, "comprising but not necessarily limited to ... ".

It is noted that some of the above described embodiments may describe the best mode contemplated by the inventors and therefore may comprise structure, acts or details of structures and acts that may not be essential to the invention and which are described as examples. Structure and acts described herein are replaceable by equivalents, which perform the same function, even if the structure or acts are different, as known in the art. Therefore, the scope of the invention is limited only by the elements and limitations as recited in the appended claims.

Claims

WHAT IS CLAIMED IS:

1. A device for hanging an object on a drywall structure, the device comprising:

(a) a surface attachment arrangement including: (i) a substantially planar surface, and

(ii) a quantity of adhesive deployed on said surface for attachment to a surface of the drywall structure;

(b) a penetration element configured for penetrating into the drywall structure; and

(c) a mechanical linkage interconnecting between said surface attachment arrangement and said penetration element such that, when the device is deployed with said penetration element penetrating into the drywall structure and said surface attachment arrangement attached to the surface of the drywall structure, attachment of said surface attachment arrangement opposes withdrawal of said penetration element from the drywall structure.

2. A device for hanging an object on a drywall structure, the device comprising:

(a) a first layer of compressible material having a first surface and a second surface; (b) adhesive deployed on said first surface for attaching the device to the drywall structure; and

(c) a second layer of flexible, substantially non-compressible material bonded to said second surface of said first layer, said first and second layers being configured such that, when a penetrating element penetrates through said second and first layers, said second layer deforms locally so as to form a locking formation opposing withdrawal of the penetrating element.

3. The device of claim 2, wherein said first layer has a thickness of at least about 0.5 millimeter.

4. The device of claim 2, wherein said second layer has a thickness of at least about 0.4 millimeter.

5. The device of claim 2, wherein said first layer is formed from foam-like material.

6. The device of claim 2, wherein said second layer is formed from plastic.

7. The device of claim 2, wherein said adhesive is applied substantially continuously over said first surface of said first layer, the device further comprising a peel-off covering for covering said adhesive prior to use.

8. The device of claim 2, further comprising a penetrating element penetrating through said second and first layers.

9. The device of claim 2, wherein said first and second layers are bonded by an additional layer of adhesive.

10. A method for hanging an object from a drywall structure, the method comprising:

(a) attaching to the drywall structure a hanging device including:

(i) a first layer of compressible material having a first surface for attachment to the drywall structure and a second surface, and

(ii) a second layer of flexible, substantially non-compressible material bonded to said second surface; and

(b) driving a penetrating element through said second and first layers so that said second layer deforms locally to form a locking formation opposing withdrawal of the penetrating element.

11. A drywall hanging device comprising:

(a) a foam-like self-adhesive pad; and

(b) a hard flexible layer attached to said self-adhesive pad, such that, when a nail is driven through the device, the material of the hard flexible layer bends in around the nail, locking the nail in place.

12. A device for hanging an object on a drywall structure, the device comprising:

(a) an integrally formed block including:

(i) a nib for penetrating into the drywall structure, and

(ii) a flange at least partly circumscribing a base of said nib, said flange presenting a substantially flat attachment surface;

(b) an adhesive configuration bonded to said attachment surface and configured to attach said flange to a surface of the drywall structure; and

(c) a hanging configuration attached to or integrally formed with said block, said hanging configuration being configured for supporting an object.

13. The device of claim 12, wherein said block is integrally formed from plastic.

14. The device of claim 12, wherein said nib is rotationally symmetric about a longitudinal axis.

15. The device of claim 12, wherein a major part of said nib is substantially cylindrical.

16. The device of claim 12, wherein said nib is substantially conical.

17. The device of claim 12, wherein said nib has an extensional direction perpendicular to said attachment surface.

18. The device of claim 12, wherein said flange completely circumscribes said nib.

19. The device of claim 12, wherein at least one dimension of said flange is greater than a length of said nib projecting from said flange.

20. The device of claim 12, wherein said adhesive configuration includes:

(a) a layer of resilient material having a first face bonded to said attachment surface, and

(b) adhesive deployed on a second face of said layer for attaching said flange to the surface of the drywall structure.

21. The device of claim 20, further comprising a peel-off covering for covering said adhesive prior to use.

22. The device of claim 20, wherein said first face is bonded to said attachment surface by adhesive.

23. The device of claim 12, wherein said adhesive configuration is implemented as a quantity of adhesive deployed directly on said attachment surface.

24. The device of claim 12, wherein said hanging configuration is integrally formed with said block.

25. The device of claim 12, wherein said hanging configuration includes a hook.

26. The device of claim 12, wherein said hanging configuration includes a rotationally symmetric wire-retention configuration.

27. The device of claim 12, wherein said block is rotationally symmetric.

28. A drywall hanging device comprising:

(a) a flange;

(b) a nib extending from a first side of the flange;

(c) a hook-like projection extending from an opposite side of the flange; and

(d) an adhesive pad on said first side of the flange.