Title: Sheer resistant fastener assembly
Abstract: A shear resistant fastener assembly for supporting structures from a wall behind which there are no supporting framework, the wall defining therethrough an opening having a predetermined size and configuration and bordered by an interior peripheral surface having the thickness of the wall, the fastener assembly comprising an anchor plate having a predetermined length and a predetermined width and adapted to be inserted through the opening in the wall and to be positioned flatly against the rear surface of the wall, and an insert having a predetermined size and having a configuration the same as that of the wall opening and adapted to fit closely within the opening and against the interior peripheral surface of the opening, and including an arrangement for connecting together the anchor plate and the insert. The shear resistant fastener assembly also is adapted to secure together overlapping panels behind which there are no structural supporting members.
Patent Number: 6,893,199 Issued on 05/17/2005 to Michels
| Inventors:
|
Michels; Larry (512 Rock Springs Rd., Kingsport, TN 37664)
|
| Appl. No.:
|
003785 |
| Filed:
|
November 26, 2001 |
| Current U.S. Class: |
411/340; 411/344 |
| Intern'l Class: |
F16B 021/00 |
| Field of Search: |
411/340-346,546
52/698
403/384,386,388,260
|
References Cited [Referenced By]
U.S. Patent Documents
| 991426 | May., 1911 | Clements.
| |
| 2018251 | Oct., 1935 | Croessant.
| |
| 2916235 | Dec., 1959 | Nagel.
| |
| 3248994 | May., 1966 | Mortensen.
| |
| 4294156 | Oct., 1981 | McSherry et al.
| |
| 4502826 | Mar., 1985 | Fafard.
| |
| 5236293 | Aug., 1993 | McSherry et al.
| |
| 5275518 | Jan., 1994 | Guenther.
| |
| 5944466 | Aug., 1999 | Rudnicki et al.
| |
| 6007285 | Dec., 1999 | Sisto et al.
| |
| 6062785 | May., 2000 | McDermott.
| |
| 6161999 | Dec., 2000 | Kaye et al.
| |
| 6287065 | Sep., 2001 | Berlin.
| |
Primary Examiner: Miller; William L.
Attorney, Agent or Firm: Dunn; Malcolm G.
Claims
1. A shear resistant fastener assembly for supporting structures from a wall
having a predetermined thickness and behind which there are no supporting studs,
the wall defining therethrough an opening having a predetermined size and a predetermined
configuration and bordered by an interior peripheral surface having said thickness
of said wall, said fastener assembly comprising:
a) an anchor plate means for attachment to said wall and having a predetermined
length, a predetermined width and a predetermined thickness and defining at least
a flat front surface, said anchor plate means adapted to be inserted through said
opening in said wall and for its flat front surface to be positioned flatly against
the rear surface of said wall;
b) An insert means for connecting to said anchor plate means and for fitting
closely within said opening and into engagement against said interior peripheral
surface of said opening, said insert means defining a center and having a predetermined
size and a predetermined configuration that are the same as that of said opening
and defining a flat front surface and a flat rear surface; and
c) means for connecting together said anchor plate means and said insert means
and adapted to urge said anchor plate means and its flat front surface toward and
against the flat rear surface of said insert means and also flatly against said
rear surface of said wall;
d) said anchor plate means extending along its said predetermined length a predetermined
distance from said center of said insert means and from one side of said insert
means and also at a predetermined distance from said center of said insert means
and from the other side of said insert means and being adapted to be attached to
said wall by at least one fastener structure extending through the wall and into
said anchor plate means at any location space from said insert means along said
predetermined length of said anchor plate means.
2. A shear resistant fastener assembly as defined in claim 1, and wherein said
anchor plate means has a rectangular configuration having said predetermined width
and said predetermined thickness, each being less than said predetermined size
of said opening so as to enable the introduction of the anchor plate means through
said opening, and said predetermined length of said anchor plate means being greater
than said predetermined size of said opening.
3. A shear resistant fastener assembly as defined in claim 2, and wherein said
anchor plate means, when inserted through said opening, is rotatable around said
insert means to position said anchor plate means to a predetermined position relative
to the rear surface of said wall for receiving said fastener structure through
said wall at the location of said predetermined position to which the anchor plate
means has been rotated and into the anchor plate means along its said predetermined
length spaced from said insert means.
4. A shear resistant fastener assembly as defined in claim 2, and wherein said
insert means and said opening in said wall are circular in configuration and said
insert means defines on its front surface at its outer periphery a flanged lip
adapted to be engaged against the front surface of said wall.
5. A shear resistant fastener assembly as defined in claim 1, and wherein said
anchor plate means has a rectangular configuration, the width and thickness of
which is less than said opening and the length of which is greater than said opening
and extends a greater distance from the center of said insert means on one side
of said insert means than from its other side.
6. A shear resistant fastener assembly as defined in claim 5, and wherein said
insert means and said anchor plate means are secured together and said insert means
includes a handle detachably connected to the center of said front surface of said
insert means, said handle adapted to aid in manually manipulating said anchor plate
means for insertion through said opening and to hold same in a predetermined position
against the rear surface of said wall until said anchor plate means is secured
against the rear surface of said wall.
7. A shear resistant fastener assembly as defined in claim 6, and wherein said
insert means has on its front flat surface an indicating mark pointing toward the
center of the width of said anchor plate means to show the location of said anchor
plate means when it is out of sight behind said wall.
8. A shear resistant fastener assembly as defined in claim 5, and wherein said
insert means and said opening in said wall are circular in configuration and said
insert means defines a front surface and a rear surface and also defines on its
front surface at its outer periphery a flanged lip adapted to be engaged against
the front surface of said wall.
9. A shear resistant fastener assembly as defined in claim 1, and wherein said
insert means defines on its front surface at its outer periphery a flanged lip
adapted to be engaged against the front surface of said wall.
10. A shear resistant fastener assembly as defined in claim 1, and wherein said
means for connecting together said anchor plate means and said insert means includes
a threaded screw extending through said center of said insert means and into said
anchor plate means.
11. A shear resistant fastener assembly as defined in claim 1, and wherein said
anchor plate means and said insert means each defines a pair of guide holes formed
at diametrically opposite locations in and through said insert means and formed
at diametrically opposite locations in and through said anchor plate means, each
of said pair of guide holes at one of said diametrically opposite locations in
said insert means being in direct axial alignment with one of said pair of guide
holes at one of said diametrically opposite locations in said anchor plate means;
and wherein said means for connecting together said anchor plate means and said
insert means includes a flexible loop member having two distal ends each of which
spaced from the other has been slidingly extended through one of said pair of guide
holes in said insert means and through the corresponding axially aligned guide
hole in said anchor plate means for securement at the rear surface of said anchor
plate means; said flexible loop member, when said anchor plate means is positioned
out of sight behind said rear surface of said wall and said insert means is in
position within said interior peripheral surface of said opening, upon being manually
pulled urges the anchor plate means to be brought against said rear surface of
said wall and into direct axial alignment of its pair of guide holes with the pair
of guide holes in said insert means.
12. A shear resistant fastener assembly as defined in claim 11, and wherein said
insert means and said opening in said wall are circular in configuration and said
insert means defines on its front surface at its outer periphery a flanged lip
adapted to be engaged against the front surface of said wall.
13. A shear resistant fastener assembly as defined in claim 11, and wherein said
anchor plate means has a rectangular configuration, the width and thickness of
which is such as to enable the introduction of the anchor plate through said opening
having said predetermined size and configuration, and the length of which is greater
than said predetermined size and configuration of said opening, the length of said
anchor plate means being centered with respect to the center of said insert means.
14. A shear resistant fastener assembly as defined in claim 11, and wherein said
anchor plate means has a rectangular configuration, the width and thickness of
which is less than said predetermined size and configuration of said opening, and
the length of which is greater than said predetermined size and configuration of
said opening and extends a greater distance from the center of said insert means
on one side of said insert means than from its other side.
15. A shear resistant fastener assembly as defined in claim
14, and wherein
said insert means and said opening are circular in configuration and said insert
means includes an outer annular sleeve member adapted to engage against said interior
peripheral surface of the opening in said wall.
16. A shear resistant fastener assembly as defined in claim 14, and wherein said
insert means and said opening in said wall are circular in configuration and said
insert means defines a circular core member having a circular peripheral surface
and includes an annular sleeve encircling and engaging said circular peripheral
surface, said annular sleeve having a front surface and a rear surface and defining
on its front surface at its outer periphery a flanged lip adapted to be engaged
against the front surface of said wall.
17. A shear resistant fastener assembly as defined in claim 1, and wherein said
insert means and said opening in said wall are circular in configuration and said
insert means includes an outer annular sleeve member adapted to engage against
said interior peripheral surface of the opening in said wall.
18. A shear resistant fastener assembly as defined in claim 17, and wherein said
anchor plate means and said insert means each defines a pair of guide holes formed
at diametrically opposite locations in and through said insert means and formed
at diametrically opposite locations in and through said anchor plate means, each
of said pair of guide holes at one of said diametrically opposite locations in
said insert means being in direct axial alignment with one of said pair of guide
holes at one of said diametrically opposite locations in said anchor plate means;
and wherein said means for connecting together said anchor plate means and said
insert means includes a flexible loop member having two distal ends each of which
spaced from the other has been slidingly extended through one of said pair of guide
holes in said insert means and through the corresponding axially aligned guide
hole in said anchor plate means for securement at the rear surface of said anchor
plate means; said flexible loop member, when said anchor plate means is positioned
out of sight behind said rear surface of said wall and said insert means is in
position within said interior peripheral surface of said opening, upon being manually
pulled urges the anchor plate means to be brought against said rear surface of
said wall and into direct axial alignment of its pair of guide holes with the pair
of guide holes in said insert means.
19. A shear resistant fastener assembly as defined in claim 1, and wherein said
insert means and said opening in said wall are circular in configuration and said
insert means defines a circular core member having a circular peripheral surface
and includes an annular sleeve encircling and engaging against said circular peripheral
surface, said annular sleeve having a front surface and a rear surface and defining
on its front surface at its outer periphery a flanged lip adapted to be engaged
against the front surface of said wall.
20. A shear resistant fastener assembly as defined in claim 19, and wherein said
anchor plate means and said insert means each defines a pair of guide holes formed
at diametrically opposite locations in and through said insert means and formed
at diametrically opposite locations in and through said anchor plate means, each
of said pair of guide holes at one of said diametrically opposite locations in
said insert means being in direct axial alignment with one of said pair of guide
holes at one of said diametrically opposite locations in said anchor plate means;
and wherein said means for connecting together said anchor plate means and said
insert means includes a flexible loop member having two distal ends each of which
spaced from the other has been slidingly extended through one of said pair of guide
holes in said insert means and through the corresponding axially aligned guide
hole in said anchor plate means for securement at the rear surface of said anchor
plate means; said flexible loop member, when said anchor plate means is positioned
out of sight behind said rear surface of said wall and said insert means is in
position within said interior peripheral surface of said opening, upon being manually
pulled urges the anchor plate means to be brought against said rear surface of
said wall and into direct axial alignment of its pair of guide holes with the pair
of guide holes in said insert means.
21. A shear resistant fastener assembly for securing together overlapping panel
members behind which there are no structural supporting members, each panel member
having a predetermined thickness and defining therethrough an opening having the
same predetermined size and the same predetermined configuration as the opening
in the other panel member, each said opening being bordered by an interior peripheral
surface, said fastener assembly comprising:
a) an anchor plate means for attachment to said overlapping panel members and
having a predetermined length, a predetermined width and a predetermined thickness
and defining at least a flat front surface, said anchor plate means adapted to
be inserted through each of said openings in said overlapping panel members and
for its flat front surface to be positioned flatly against the rear surface of
the innermost panel member of said overlapping panel members;
b) an insert means for connecting to said anchor plate means and for fitting
closely within said openings and into engagement against said interior peripheral
surface of each said opening, said insert means defining a center and having a
predetermined size and a predetermined configuration that are the same as that
of each of said openings in said panel members and having a predetermined thickness
that is the same as the combined thicknesses of the overlying panel members, said
insert means defining a front surface and a flat rear surface; and
c) means for connecting together said anchor plate means and said insert means
and adapted to urge said anchor plate means and its flat front surface toward and
against the flat rear surface of said insert means and also flatly against the
rear surface of the innermost panel member of said overlapping panel members;
d) said anchor plate means extending along its said predetermined length a predetermined
distance from said center of said insert means and from one side of said insert
means and also at a predetermined distance from the center of said insert means
and from the other side of said insert means and being adapted to be attached to
said overlapping panel members by at least one fastener structure extending through
said overlapping panel members and into said anchor plate means at any location
spaced from said insert means along said predetermined length of said anchor plate means.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
Not Applicable
REFERENCE TO A MICROFICHE
Not Applicable
BACKGROUND OF THE INVENTION
When hanging any structure from a relatively thin wall panel, such as a panel
formed from a drywall, the best assurance of adequate support for such structure
is to attach the structure through the drywall and into the wood stud behind the
drywall to which the drywall is attached. Since wood studs or studs of any other
material are typically placed every sixteen (16) inches on center or every twenty-four
(24) inches on center, it is not always possible to locate the structure to be
supported so as to secure the structure through the drywall to the stud.
Numerous devices have been invented and designed over the years for the
purpose of increasing and providing more practical holding power for anchor bolts
in walls, ceilings and floors. An early example, but certainly not the earliest,
is the disclosure in the Croessant patent, U.S. Pat. No. 2,018,251 (1935), of an
anchoring socket provided for an anchor bolt. This anchoring bolt comprises a bolt-supporting
sleeve formed at the outer end of the socket, a nut secured at the inner end of
the socket, a plurality of intermediate strips circularly spaced around the socket
and connected at their respective one ends to the sleeve and connected at their
respective other ends to the nut, and a bolt, which extends through the sleeve
for threaded engagement within the nut. A suitable aperture is formed in a solid
wall of masonry, concrete or the like at the location where an article is to be
secured or supported and the aperture is of a size to enable insertion of the length
of the anchoring socket substantially within the wall thickness of the aperture.
The intermediate strips are each provided with a weakened portion at a predetermined
point along their respective lengths. When a torquing force is applied to the bolt
the nut is caused to be drawn toward the sleeve, thereby forcing a collapse or
outward buckling of the intermediate strips and causing the intermediate strips
to expand radially in a frictional gripping engagement against the interior surface
of the aperture surrounding the anchoring socket, as shown in FIG. 7 of the Croessant patent.
Another socket example is shown in FIG. 5 of the Croessant patent, wherein
the thickness of the wall is less than the length of the bolt-supporting sleeve
of the anchoring socket, and the nut and intermediate strips extend into the cavity
behind the wall. When a torquing force is applied to the bolt, which is threadedly
engaged with the nut, the nut is axially drawn toward the sleeve, and the intermediate
strips buckle or bend outwardly until the intermediate strips make engaging contact
against the inner surface of the wall in circularly spaced relation from and around
the end of the sleeve that projects into the cavity beyond the thickness of the
wall. The patentee states that this circularly spaced wall engagement by the bends
of the intermediate strips provides an enlarged base support to fixedly anchor
the nut, and to engage the wall interior surface at a location removed from any
weakness that may have been caused when the aperture was made for the anchoring socket.
In either example, as shown in FIG. 7 or in FIG. 5 in the Croessant patent, the
anchor bolt may be removed and replaced as often as necessary with no loosening
effect on the anchoring socket. Although the patentee offers no comment as to which
example has the better holding power, it should be apparent that the engagement
of the intermediate strips against the interior wall surface in the example of
FIG. 5 would provide greater holding power than the frictional gripping engagement
of the intermediate strips within the aperture in FIG. 7. Such frictional
gripping engagement would be effective for light to moderate loads, while the circularly
spaced wall engagement by the bends of the intermediate strips in FIG. 5 would
be a better choice for heavy items such as shelves, towel rods, and the like.
To summarize this early state of the prior art, the intermediate strips form
an
anchoring mechanism, and the rotation of the threaded bolt causes the anchoring
mechanism to expand and contact the rear or blind surface of the wall so as to
anchor the anchoring socket in place.
Another more recent prior art example, but again not the earliest, is shown
in the McDermott patent, U.S. Pat. No. 6,062,785 (2000), wherein the anchoring
mechanism comprises two toggle members (see FIG. 6), which are spring-biased
to expand behind the blind or rear surface of the wall when the threaded bolt is
turned and the toggle members are caused to clear a restricting sleeve that is
part of the anchoring socket and also the natural restriction against such expansion
as formed by the thickness of the wall surrounding the aperture.
Still more current prior art examples of anchoring sockets are shown in the
Rudnicki et al patent, U.S. Pat. No. 5,944,466 (1999) and the Sisto et al patent,
U.S. Pat. No. 6,007,285 (1999). The Sisto et al patent, for example, points out
some problems associated with prior art wall fasteners when used with gypsum board,
for example. For instance, when a portion of the anchor mechanism is received within
the hole prepared in the wall the 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 possible problem is that fasteners have to be installed carefully
so as to insure that they are not over-torqued. Continued twisting of the threaded
bolt after the anchor mechanism has made contact with the inner or rear surface
of the wall will cause the anchor mechanism to twist and dig into the inner surface
of the wall, thus gouging the periphery of the wall hole and destroying the paper
surfaces of a drywall, for example, thereby causing the fastener to fit loosely
within the wall because the holding power of the drywall has become lost. This
would increase the likelihood that the fastener would become dislodged from the
wall. The Sisto et al patent additionally points out that the supporting capacity/strength
of conventional fastening structures is limited by a relatively short axis of rotation
in the axial plane, the axis being defined as the distance between the points of
support provided by the anchor assembly and the threaded member (bolt). This distance
is equivalent to the thickness of the wall or wallboard, which the patentees assert
is typically far too short to support large or heavy objects due to the high concentration
of stresses over such a small area, when using, for example, a "molly" fastener.
The Sisto et al patent asserts that these problems are avoided by their fastener
assembly, which allows relatively heavy objects to be attached to either a hollow
or a solid core wall because the stresses exerted by such objects are distributed
over a relatively wide area around the wall hole in which the fastener is anchored,
and along a relatively long axial plane of support defined by their elongated cantilever
structure. Their fastener assembly includes an elongated tubular body having a
flange or face plate at its axial outer end. The tubular body defines an axial
cavity dimensioned to receive a correspondingly dimensioned support member. When
the elongated tubular body and support member are inserted into a properly dimensioned
hole formed in a suitable support structure such as a wall, or ceiling, or floor,
the rear face of the face plate contacts the portion of the support structure surface
(that is, the exterior surface of the wall) that surrounds the hole. The elongated
tubular body and the support member within the latter are maintained in position
by an anchor member which is disposed proximate the distal or opposite axial end
of the tubular body. The anchor member comprises a base portion defining a central
threaded aperture, and a plurality of elongated wings, which 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 so as to allow the anchor member
to be inserted through the wall hole. The wings are spring-biased so that they
expand outwardly from the tubular body, and in the case of a hollow wall, the wings
engage the inner surface of the wall when the anchor member clears the hole on
the interior side or rear surface of the wall. A threaded member or bolt in inserted
through the cavity of the tubular body and into the central threaded aperture of
the anchor member. As the bolt is rotated, the anchor member is drawn closer to
the face plate of the tubular body (in the case of a hollow wall). The outside
diameter of the face plate is preferably selected so that the outwardly biased
wings of the anchor member do not extend beyond the peripheral edges(s) of the
face plate. This is said to ensure that stresses are distributed only over those
portions of the surrounding wall which are in compression (that is, compression
between the face plate on the outer or exterior side of the wall and the wings
engaging the inner side or rear surface of the wall toward the face plate) and
thereby provide substantially enhanced mechanical strength and stability.
In FIG. 6 of the Sisto et al patent, a handrail assembly or grab bar is shown
being supported from a wall by two such fastener assemblies. The patentees point
out that it is frequently impossible to retrofit handrail assemblies suitable for
use by the handicapped and the elderly in bathrooms or the like due to lack of
suitably positioned mounting structures (studs, etc.). They state that it was heretofore
necessary to remove the existing wall panel and insert one or more additional studs
or other solid structures so as to provide a sufficiently reliable connection,
and that with their invention the need for such expensive retrofitting operations
is completely avoided.
The above-mentioned Rudnicki et al patent, both inventors being the same as in
the Sisto et al patent, discloses a similarly constructed and operating fastener
assembly with several different embodiments, which may be also used to join two
or more overlapping planar elements, such as in the construction of modern aircraft
where rivets are typically used to join the individual sheets of aluminum that
collectively form a skin over the air frame. Aligned holes in two overlapping members
receive therethrough the anchoring assembly, which compresses the overlapping members
together between the face plate and the anchor member positioned interiorly of
the two overlapping members. The patentees state that the joining forces are imparted
at three or more radially distributed regions that are located away from the peripheral
edges of the aligned openings in the respective elements to be fastened. The anchoring
assembly comprises three or more elongated wing members that extend from the threaded
apertured base portion toward the rear or interior surface of the face plate. once
the wing members clear the opening(s) they expand outwardly from their initial
folded position, and as the threaded bolt is rotated the anchoring assembly is
drawn closer to the face plate until respective distal tip regions of the wing
members contact corresponding interior surface regions of the inner most structural
element or wall or overlapping member, whichever the case. The regions of contact
between the distal tip regions of the anchoring assembly are radially equidistant,
that is, symmetrically arranged relative to the center of the opening, so that
joining forces are exerted at evenly distributed locations remote from the edge
of the opening while avoiding stress concentrations at the edges of the aligned
openings resulting. The supporting structure of the anchoring assembly is sufficiently
rigid as to resist continued movement of the base portion toward the face plate
when the distal regions initially contact the interior surface of the wall or structural element.
The Rudnicki et al patent also indicates that the fastener assembly may be used
to secure a kitchen cabinet or similar structure to a gypsum wall board structure.
All of these prior art fastener structures, as well as others well-known in the
art but not specifically mentioned here, serve to provide a substitute supporting
structure for drywalls, gypsum boards, any other relatively thin walls or structural
elements, as well as for overlapping panels to be joined together, where there
is an absence of a regular supporting structure therebehind, such as a stud or
frame member, and at any location where an object of any appreciable weight is
needed to be supported or to be secured, or where overlapping panels members are
needed to be joined together. All of these fastener structures have anchor members
that are designed to be radially expanded in some manner once they pass through
an opening formed in the wall, ceiling or floor, or through aligned openings formed
in overlapping panels to be joined, so as to resist withdrawal or falling out of
the anchor members through the opening.
A small diametered fastener assembly and an object of significant weight to be
supported thereby from a gypsum board forming the wall, for example, can produce
sheer forces, that is, a force that acts parallel to the plane of the gypsum board
wall, that in time, or possibly as a result of repeated vibration, such as might
be caused by repeated slamming of nearby doors connected to the wall, cause loosening
of the fastener assembly or tear-out of the fastener assembly through the wall.
The shear resistant fastener assembly disclosed herein, by the nature of its
construction, is significantly sheer resistant, and does not depend upon anchoring
structures that require radial expansion on the opposite or rear side of a wall.
An opening is formed in the wall where and from which an object is to be supported
and where there is no regular stud or framework already located behind the wall.
The opening is of a size that enables an anchor plate member of a predetermined
length and width and of a predetermined configuration to be inserted therethrough
and then oriented to any position relative to the object to be supported from the
wall. The anchor plate member is connected to an insert member, which is of the
same size and configuration as the opening and therefore is designed to fill the
opening in the wall and fit partly or wholly within the wall and be essentially
flush with the exterior side of the wall.
The anchor plate member disclosed herein has on one side a large planar surface
area that faces the rear surface of the wall and that thereafter is secured flatly
against that rear surface by conventional fastening means, such as by use of screws
that are extended through the wall and into the anchor plate member. This large
planar surface area is greater than that of any known prior art, other than what
a conventional supporting structure, such as a wood or metal stud, would provide
if it could have been conveniently positioned in the same location. In other words,
this large planar surface area provides a much greater "target" area for an installer
of cabinets or other structures and objects to more easily "hit" with a screw than
the "target" area presented by the aforementioned "molly" fastener. In the instant
invention, a two inch wide by five inch long anchor plate, as only one example
of what is easily possible to be used, the width alone is even wider than a conventional
"2 by 4" wood stud since the width of a conventional stud is actually only 1½
inches instead of 2 inches. When considering also, the mentioned five inch length
along with the two inch width, this is a significant "target" area. Further, before
the anchor plate member of the invention is secured against the wall rear surface,
it may be oriented to any position behind the wall 360 degrees around the opening
in the wall, depending upon where on the wall, an object, for example, is to be
supported; which is another significant advantage as well.
SUMMARY OF THE INVENTION
The present invention, therefore, is directed to a shear resistant fastener assembly
for supporting structures from a wall behind which there are no supporting studs,
the wall defining therethrough an opening having a predetermined size and configuration
and bordered by an interior peripheral surface having the thickness of the wall.
The shear resistant fastener assembly includes an anchor plate having a predetermined
length and a predetermined width and defining at least a flat front surface. The
anchor plate is adapted to be introduced or inserted through the opening in the
wall and for its flat front surface to be positioned flatly against the rear surface
of the wall. The shear resistant fastener assembly also includes an insert having
a predetermined size and configuration the same as that of the opening in the wall
and is adapted to fit closely within the opening and into engagement against the
interior peripheral surface of the opening; the insert defines a flat front surface
and a flat rear surface. The shear resistant fastener assembly further includes
connecting structure for connecting together the anchor plate and the insert and
is adapted to urge the anchor plate and its flat front surface toward and against
the flat rear surface of the insert and also flatly against the rear surface of
the wall.
The anchor plate has a rectangular configuration, the width and thickness of
which is such as to enable introduction of the anchor plate through the opening
in the wall, and the length of which is greater than that of the opening in the
wall. The length of the anchor plate may be centered with respect to the center
of the insert, or the length of the anchor plate may extend a greater distance
from the center of the insert on one side of the insert than from its other side.
The anchor plate, when inserted through the opening in the wall, may be rotatable
to position the anchor plate to a predetermined position relative to the rear surface
of the wall.
The insert and the anchor plate may be secured together, and the insert may include
a handle detachably connected to the center of the front surface of the insert.
The handle aids in manually manipulating the anchor plate through the opening in
the wall and for holding the anchor plate in a predetermined position against the
rear surface of the wall until the anchor plate is secured against the rear surface
of the wall.
The insert may have on its front flat surface an indicating mark pointing toward
the center of the width of the anchor plate to show the location of the anchor
plate when it is out of sight behind the wall.
The insert may define on its front surface at its outer periphery a flanged lip,
which is adapted to be engaged against the front surface of the wall when the insert
fits closely within the opening in the wall and into engagement against the interior
peripheral surface of the opening.
The insert and anchor plate may be connected together by the use of a threaded
screw extending through the center of the insert and into the anchor plate.
The anchor plate and the insert may each define a pair of guide holes formed
at diametrically opposite locations in and through the insert and formed at diametrically
opposite locations in and through the anchor plate. Each of the pair of guide holes
at one of the aforementioned diametrically opposite locations in the insert is
in direct axial alignment with one of the pair of guide holes at one of the diametrically
opposite locations in the anchor plate. The anchor plate and the insert may then
be connected together by a flexible loop member having two distal ends each of
which is spaced from the other and is slidingly extended through one of the pair
of guide holes in the insert and through the corresponding axially aligned guide
hole in the anchor plate for securement at the rear surface of the anchor plate.
When the anchor plate is positioned out of sight behind the rear surface of a wall
and the insert is in position within the interior peripheral surface of the opening
in the wall, the flexible loop is manually pulled to urge the anchor plate against
the rear surface of the wall and into direct axial alignment of its pair of guide
holes with the pair of guide holes in the insert.
The insert and the opening in the wall may be circular in configuration and the
insert may include an outer annular sleeve member adapted to engage against the
interior peripheral surface of the opening in the wall.
The insert and the opening in the wall may be circular in configuration, and
the insert may define a circular core member having a circular peripheral surface
and include an annular sleeve encircling and engaging against the circular peripheral
surface. The annular sleeve has a front surface and a rear surface and defines
on its front surface at its outer periphery a flanged lip adapted to be engaged
against the front surface of the wall.
The shear resistant fastener assembly may also be used to secure together overlapping
panels behind which there are no supporting structural. The overlapping panels
define through the panels aligned openings having the same predetermined size and
configuration and are bordered by interior peripheral surfaces having the collective
thicknesses of the overlapping panels. The shear resistant fastener assembly includes
an anchor plate having a predetermined length and a predetermined width and defines
at least a flat front surface and is adapted to be inserted through the openings
in the overlapping panels and for the front surface of the anchor plate to be positioned
flatly against the rear surface of the innermost panel of the overlapping panels.
The insert has a predetermined size and configuration the same as that of the openings
in the overlapping panels and is adapted to fit closely within the openings and
into engagement against the interior peripheral surfaces of the openings and defines
a flat front surface and a flat rear surface. A connecting member is provided to
connect together the anchor plate and the insert and is adapted to urge the anchor
plate and its flat front surface toward and against the flat rear surface of the
insert and also flatly against the rear surface of the innermost panel of the overlapping panels.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of the shear resistant fastener assembly of the invention
having a circular insert and a rectangular anchor plate secured together with the
anchor plate being shown in dotted lines because when installed through a hole
in the drywall it is hidden behind the drywall; it also shows a handle detachably
attached to the insert and by which the anchor plate is manipulatively inserted
through the hole made in the drywall, and further showing that the anchor plate
may be potentially rotatable 360 degrees around the hole in the drywall after insertion
of the anchor plate behind the drywall;
FIG. 2 is a side elevation view in cross-section of the shear resistant fastener
assembly, detachable handle and drywall shown in FIG. 1;
FIG. 3 is an isometric, exploded view of the shear resistant fastener assembly
of the invention and illustrating an insert having a rectangular configuration;
FIG. 4 is an isometric view of part of a drywall, its edge partially shown in
cross-section, and illustrating the hole formed through the drywall within and
through which the shear resistant fastener assembly will be installed and also
illustrating the interior peripheral surface defining the hole in the drywall;
FIG. 5 is a plan view of the shear resistant fastener assembly of the invention
installed within and through a hole in a drywall, and illustrating a reposition
of the insert shown in FIGS. 1 and 2 so that the insert is positioned within the
length of the anchor plate and is closer to one end of the anchor plate than from
the other end, the anchor plate being shown in dotted lines because it is hidden
when installed behind the drywall, and further illustrating that the anchor plate
is potentially rotatable 360 degrees when positioned behind the drywall;
FIG. 6 is a side elevation view in cross-section of the shear resistant fastener
assembly shown in FIG. 5 and shows the drywall in cross-section;
FIG. 7 is a plan view of the shear resistant fastener assembly illustrating
the circular insert as being centered with respect to the length of the anchor plate;
FIG. 8 is a side elevation view in cross-section of the shear resistant fastener
assembly shown in FIG. 7;
FIG. 9 is a front elevation view of a cabinet supported from a drywall by two
shear resistant fastener assemblies, which are shown in dotted lines because when
installed they are both hidden behind the rear wall of the cabinet;
FIG. 10 is an isometric, exploded view of a safety grab bar, which is supported
from a tiled wall that is secured to the drywall, and illustrates two shear resistant
fastener assemblies, each at a respective end of the safety grab bar to provide
support for the safety grab bar and illustrates one example of how the safety grab
bar may be installed by use of the shear resistant fastener assemblies of the invention;
FIG. 11 is a side elevation view in cross-section of another embodiment of the
shear resistant fastener assembly installed within a drywall, also shown in cross-section,
and illustrates the circular insert as having a circular core circumferentially
surrounded by a sleeve, and that the sleeve has formed at its outer front surface
a flanged lip for bearing against the front surface of the drywall around the edge
of the hole formed in the drywall for insertion within of the shear resistant fastener assembly;
FIG. 12 is a side elevation view of still another embodiment of the shear resistant
fastener assembly shown in cross-section and in which the insert has a integrally
formed flanged lip, and the insert is illustrated as being loosely connected to
the anchor plate by a flexible loop member prior to the insert being inserted within
the hole in the drywall, also shown in cross-section, and also illustrating the
anchor plate prior to its being drawn flatly against the rear surface of the drywall
by the flexible loop member;
FIG. 13 is a side elevation view in cross-section of the shear resistant fastener
assembly embodiment shown in FIG. 12, and illustrating the insert positioned within
the hole in the drywall, also shown in cross-section, and illustrating the anchor
plate having been pulled flatly against the rear surface of the drywall by the
flexible loop member, the pulling action also serving at the same time to automatically
align the respective guide holes with each other;
FIG. 14 is a plan view of the shear resistant fastener assembly embodiment shown
in FIGS. 12 and 13, and illustrating the anchor plate in dotted lines because it
is hidden behind the drywall;
FIG. 15 is a side elevation view in cross-section of two overlapping panel members
secured together by the shear resistant fastener assembly of the invention, also
shown in cross-section; and
FIG. 16 is a plan view of the two overlapping panel members and the shear resistant
fastener assembly shown in FIG. 15.
DETAILED DESCRIPTION OF THE INVENTION
In reference to the drawings, and initially to FIGS.
1 and
2, the
shear resistant fastener assembly of the invention is shown at
10 and is
for use in supporting objects or structures of various weights from wall panels,
such as wall panels formed by drywalls. A drywall typically has a gypsum core sandwiched
between heavy paper, the heavy paper providing the shear resistance for the drywall,
and the drywall may, for example, be one-half (½) inch or five-eights (⅝)
inch in thickness, the latter, obviously being the stronger of the two thicknesses.
Other thicknesses for drywall are possible, but the ones mentioned are typically
used in home and building constructions.
The shear resistant fastener assembly
10 comprises two main elements:
an insert
12 and an anchor plate
14. The "insert" is called such
because it is designed to be inserted or to fit partly or wholly within the wall
panel. The preferred configuration of the insert is circular for ease of formation,
but it should be understood that the insert may also have a rectangular configuration,
such as shown by the shear resistant fastener assembly
10′ in FIG.
3, which shows a rectangular insert
12′ along with the rectangular
anchor plate
14′. The insert may also have a hexagonal or octagonal
configuration or any other configuration (these are not shown). These other configurations
are mentioned only to show that the concept of the invention should not be limited
to circular inserts, even though the circular configuration is much easier to form,
as by a hole saw, and is, therefore, much more practical in application. The "anchor
plate" is called such because it is designed to be suitably anchored against the
flat surface of the rear wall of the drywall or wall panel.
The anchor plate
14 is preferably rectangular in configuration, and has
a predetermined width, a predetermined length and a predetermined thickness. The
anchor plate
14 has at the very least a flat front surface
16 for
engaging or being anchored flatly against the flat rear surface of a drywall, for example.
As shown in FIGS. 1 and 2, the shear resistant fastener assembly
10 is
installed within the drywall
18. The anchor plate
14 has been introduced
through the hole
20 made in and through the drywall and into the cavity
(not shown) that is naturally formed behind the drywall and between the supporting
studs or framework (not shown). Since the dimensions of a wood stud, for instance,
to which a drywall is applied is usually 1½ inches by 3½ inches, the
depth of the cavity would be at least 3½ inches. The anchor plate itself must
have a width and a thickness that is less than that of the opening
20 in
the drywall so that the anchor plate may be inserted through the opening. The preceding
indicated depth of the cavity is usually sufficient to enable the manipulative
insertion of a fairly long anchor plate, such as one being about five inches in
length, for example. The latter length, or it could be of a lesser length within
reason, is usually sufficient to provide an adequate anchoring structure into which
screws may be inserted, with the screws passing first through the object or structure
to be supported from the drywall, and through the drywall.
After insertion of the anchor plate, but before securing it to the drywall
with the aforementioned screws, the anchor plate may be oriented to a predetermined
position by rotating it relative to the hole
20 to a position where it is
deemed needed. The anchor plate, therefore, is potentially rotatable 360 degrees,
as shown in FIG.
1. The final position of the anchor plate depends upon
where an object or other structure is to be supported from the drywall
18.
When the anchor plate
14 is introduced into the cavity behind the drywall,
the anchor plate, obviously, becomes hidden from view by the drywall. In order
to determine its location, an indicator mark
24 may be placed on the front
surface
26 of the insert
12 after the insert and anchor plate have
been suitably secured together. In this manner, and knowing beforehand the length
and width of the anchor plate, a person using this invention only has to measure
along the front surface of the drywall from the mark on the front surface
26
of the insert to determine the outlines of the length and width where the anchor
plate will be located behind the drywall and insert within these outlines screws
through the drywall and into the anchor plate behind the drywall.
One main purpose of the shear resistant fastener assembly
10 is its use
for supporting objects or structures, such as cabinets, safety grab bars, towel
racks, toilet paper holders, book shelves, and many other structures having various
weights, from a wall behind which there are no supporting studs or frame work in
the areas where the objects or structures are to be mounted.
Since supporting studs are usually positioned sixteen (16) or twenty-four (24)
inches on center, it is not always possible to support an object or structure from
a drywall, for instance, by connecting directly through the drywall and into a
supporting stud. Obviously, if it were known beforehand where a structure is to
be supported, adequate supporting studs or framework could have been installed
before the drywall was installed. In most instances, however, decisions as to where
some structure is to be supported are made some time after the drywall has already
been installed. It is not very convenient later to remove portions of the drywall
to install additional supporting structures behind where the drywall is installed
and then replace the removed portions of the drywall.
Modern bathtubs, shower stalls, and the walls adjacent toilets may often incorporate
safety grab bars so as to provide support to the people using same. The safety
grab bars can be fastened to structural framing members through the walls behind
where the safety grab bar(s) is or are to be supported. Such grab bars can be mounted
vertically, horizontally, or diagonally and at different heights to accommodate
the individual's requirements.
One arrangement that may be employed for manipulating the anchor plate into and
through the opening
20 and then for drawing the anchor plate flatly against
the rear surface
28 of the drywall is by use of a detachable handle
30,
as shown in FIGS. 1 and 2. The insert and the anchor plate
14 may first
be suitably connected together, as by gluing and then adding screws or small nails
32 (see FIG.
2), and then the handle may be temporarily secured to
the front face of the insert by a wood screw
34 extending through the axial
center of the handle and into the insert and anchor plate, as shown. It should
be noted here, that the insert and anchor plate may also be molded in one piece,
as from a suitable plastic or other comparably moldable, injectionable or pressable
material, thus eliminating the need for gluing and nailing the insert and anchor
plate together. Once the anchor plate is introduced into the cavity behind the
drywall, the person manipulating the handle may cause the anchor plate to be drawn
flatly against the rear surface
28 of the drywall until one or more drywall
screws
36 (see FIG. 2) have been inserted through the drywall and into the
anchor plate to secure it or anchor it to the rear surface
28 of the drywall.
Thereafter, the handle and wood screw are removed and then screws are inserted
through the object or structure to be supported from the drywall, through the drywall,
and then into the anchor plate.
In the embodiment of the invention shown in FIGS. 1 and 2, the circular insert
12 has been positioned at one end of the anchor plate and extends or overlaps
partly beyond the length and width of the anchor plate
14 so as to facilitate
introduction or insertion of the anchor plate, as pre-connected to the circular
insert
12, through the opening
20 in the drywall
18. It will
be observed from FIG. 2 that the thickness of the circular insert
12 is
shown as being of the same thickness as the drywall
18. The shear resistant
fastener assembly
10, however, may also be used where the thickness of the
drywall may be greater than the thickness of the circular insert (not shown), which
would result in the front surface
26 of the circular insert
12 being
recessed with respect to the front surface
38 of the drywall
18.
This latter situation would not matter from the standpoint of appearance because
the resulting recess would subsequently be obscured by whatever object or structure
that is to be supported from the drywall by the shear resistant fastener assembly
10.
In reference above to the discussion of the use of the shear resistant fastener
assembly
10 for safety grab bars, as well as for other uses,
The Standard
Consumer Safety Specification for Grab Bars and Accessories Installed in the Bathing
Area, for instance, requires that grab bars installed horizontally be able
to withstand an applied downward load of 250 pounds. This amount of loading is
to be applied over a 3½ inch area in the center of the grab bar for a period
of five minutes, and there must be no visible damage during such loading. During
this time the grab bar must not break or fail. The purpose of these tests is to
assure that persons using the grab bars are enabled to maintain their balance,
to prevent their falling or to assist them in exiting and entering.
The area of frictional contact of the anchor plate
14 against the rear
surface of the drywall is quite significant. For instance, if the anchor plate
should be five inches long by two inches wide, as previously suggested, the area
of contact would be ten (10) square inches. If a safety grab bar were to be connected
at both of its respective ends to two such shear resistant fastener assemblies
10, the weight possible to be supported by the safety grab bar would far
exceed the minimum requirement of 250 pounds, as specified by the aforementioned
ASTM F 446-85 standard. A drywall having a thickness, for example, of five-eights
(⅝) inch would greatly resist tear-out over such a large square area, assuming
proper surface preparation beforehand against deterioration of the drywall from
any possible moisture in the bathroom environment.
Referring again to the insert
12, the size of the insert, as i
