Abstract:
The instant invention is directed to an apparatus and methods for restraining a water heater to a supporting structure, such as a wall. The fastening system includes at least one bracket which mounts to the supporting structure and at least one restraining strap, one end of which attaches to a bracket, the other end of which can attach to another bracket, or mount directly to the wall, to hold the water heater tightly against the supporting structure. In some embodiments, the strap is long enough to encircle the water heater. In other embodiments, the strap can be split into two straps and joined at the water heater with tension buckles. In the preferred embodiment, two straps are used, and both are secured to the supporting structure with brackets. One of the straps encircles the water heater, and both connect to each other at the water heater through tension buckles. In the preferred embodiment, the connection of a strap to its tension buckle is made by a single slot, which contains a pointed tab which pierces a hole in the strap to securely fasten the strap to the tension buckle.

Description:
This application is a continuation of application Ser. No. 09/097,369, filed Jun. 15, 1998, now U.S. Pat. No. 6,145,796, which is a continuation-in-part of application Ser. No. 09/069,372, filed Apr. 29, 1998 now abandoned, for an apparatus and method for securing a water heater to a wall utilizing straps. 
    
    
     FIELD OF THE INVENTION 
     This invention is directed to apparatus and methods for securing a water heater to a supporting structure utilizing straps. 
     BACKGROUND OF THE INVENTION 
     Water heaters provide a valuable convenience in the modern home in that they supply hot water to the occupants of the household upon demand. Unfortunately, water heaters also introduce dangers into the home. Indeed, natural disasters, such as, for example, earthquakes or flooding, can cause the water heater to overturn or pull from the wall such that damage to the gas line occurs causing the release of natural gas which can then ignite. The igniting of the natural gas can destroy the house, and potentially the occupants, if the fire is not immediately contained. 
     In an effort to avoid such disasters, some state legislatures, e.g., California, have passed laws requiring the securing of the water heater to the wall or to the floor. These requirements have aided in reducing the number of disasters caused from damaged water heaters. 
     One device directed to the restraint of water heaters is described in U.S. Pat. No. 5,487,518 to McCraney. In the McCraney reference, an elongated strut is secured to a wall. Strapping is attached to a pair of triangular gussets which are then attached to the strut and connected together with a pair of tensioning buckles. The gussets are slidably coupled to the strut such that the gussets can be independently positioned depending upon the position of the studs in the wall. Although this design provides a sturdy restraint, it is time consuming to install due to the numerous parts. Another drawback of this design is the difficulty encountered in threading the straps through the two slots in the tensioning buckle. Further, the design in the McCraney reference does not allow the water heater to be retrofitted; rather, the water heater must be removed from the wall to install the restraint. Additionally, this design is limited in the scope of installation in that the elongated strut requires a flat wall for attachment, thus, the water heater must also be located against this flat wall. 
     A need exists in the industry for a restraining device that is safe, inexpensive and allows for ease of installation. Further, a need exists for a restraining device that can be retrofitted to existing water heaters such that the water heater does not need to be removed from the wall to install the restraining device. A need further exists for a restraining device that allows installation of the water heater with varying types of spaces, such as, rounded corners. 
     SUMMARY OF THE DISCLOSURE 
     The instant invention is directed to an apparatus and method for securing a water heater, and the like, to a wall or floor that is capable of retrofitting currently installed water heaters, and further allows installation in virtually any type of environment. Further, embodiments of the instant invention include flexible brackets that directly grip the restraining strap such that the strength and integrity of the restraining strap at the brackets is retained. However, it should be noted that lower cost embodiments, where strap length adjustability at a wall is not required, include versions where the strap is attached directly, without a bracket, to a wall or floor through a hole in the strap. 
     Preferred embodiments of the instant invention include restraining straps and a plurality of brackets, wherein the brackets are configured to receive the straps. A first end of the straps are threaded through the brackets which are then attached to the studs in the wall. The straps are then coupled together in the front of the water heater. In one preferred embodiment, at least one of the straps is as long as the measured circumference of the water heater. Other preferred embodiments further include tension buckles and a spacer. 
     In embodiments utilizing tension buckles, the second end of the straps are threaded through tension buckles which reside in the front of the water heater. The tension buckles are coupled together such that the straps snugly secure the water heater. A spacer is threaded through the straps prior to securing the straps to the tension buckles. The spacer is placed in the back of the water heater between the water heater and the wall. This aids in preventing the water heater from damaging or being damaged by hitting the wall. 
     Another advantage to the preferred embodiment of the new tension buckle is ease of installation. The new tension buckle with tab is much easier to install than the previous two slot tension buckle because one simply slides the strap through one slot, instead of the two slots on the previous tension buckle. The tab in the first slot engages with one of several perforations in the strap to provide for secure attachment, without a second slot. A further advantage of the tension buckle with pointed tab is that as the strap is tightened, the pointed tab pierces its own hole in the strap so it can provide secure attachment without the need for either a perforated strap or second slot. 
     Another feature of embodiments of the instant invention is that the length of the restraining straps can be adjusted. Advantages of the adjustability of the length of the straps is that the device is operable with larger or smaller size water heaters. 
     A further feature of embodiments of the instant invention is that there are relatively few pieces comprising the restraint. An advantage of fewer parts is that installation of the restraining device is easy. 
     Still a further feature of embodiments of this invention is that the buckles can be installed in any position. At least one advantage of this feature is that the restraining device is not limited in the environment required for installation. A further advantage of this feature is that the water heater does not have to be removed from the wall to install the restraining device, thereby allowing previously installed water heaters to be retrofitted with the restraining device. 
     A feature of the brackets in preferred embodiments is that the brackets allow the storage of the ends of the straps to be folded behind the water heater. An advantage of this feature is that the safety of the fastening system is enhanced as the potentially sharp edges of the straps are less exposed to people walking by the water heater. 
     Another feature of preferred embodiments of the instant invention include a spacer that, in operation, is disposed between the water heater and the wall. An advantage to this feature is that in instances wherein a separation of the water heater from the wall is required, for example, in non-zero clearance water heaters, the spacer is a true retrofit and holds the water heater from the wall, thereby, increasing the safety of the water heater. 
     The above and other advantages of embodiments of this invention will be apparent from the following more detailed description when taken in conjunction with the accompanying drawings. It is intended that the above advantages can be achieved separately by different aspects of the invention and that additional advantages of this invention will involve various combinations of the above independent advantages such that synergistic benefits may be obtained from combined techniques. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The detailed description of preferred embodiments of the invention will be made with reference to the accompanying drawings, wherein like numerals designate corresponding part the figures. 
     FIG. 1 is a perspective view of the fastening system of the present invention. 
     FIG. 2 a  is a perspective view of the bracket of the fastening system in FIG. 
     FIG. 2 b  is a perspective view of the bracket in FIG. 2 a , wherein the bracket further includes a tooth. 
     FIG. 2 c  is a perspective view of an alternative bracket of the fastening system in FIG.  1 . 
     FIG. 2 d  is a perspective view of the alternative bracket in FIG. 2 c , wherein the bracket further includes a tooth. 
     FIG. 3 a  is a top view of the bracket shown in FIG. 2 a.    
     FIG. 3 b  is a top sectional view of the bracket shown in FIG. 2 a  taken along line  3   b—   3   b.    
     FIG. 4 is a perspective view of the tension buckles of the fastening system in FIG.  1 . 
     FIG. 5 a  is a top view of the fastening system of FIG. 1 securing a water heater to a wall. 
     FIG. 5 b  is a top view of the fastening system of FIG. 1 securing a water heater in a corner of two adjoining walls. 
     FIG. 6 is a perspective view of a spacer of the fastening system FIG.  1 . 
     FIG. 7 a  is a top view of a strap threaded into the bracket of the fastening system of FIG.  1 . 
     FIG. 7 b  is a top view of the strap fastened to the bracket of FIG. 7 a.    
     FIGS. 8 a-   8   c  illustrate a strap being threaded through a tension buckle. 
     FIG. 9 a  is a perspective view of a second preferred embodiment of the fastening system of the present invention. 
     FIG. 9 b  is a perspective view of a third preferred embodiment of the fastening system of the present invention without the tension buckles or spacer and with only one bracket. 
     FIG. 10 is a perspective view of an alternative embodiment of the tension buckles of the fastening system of FIG.  1 . 
     FIGS. 11 a-   11   c  illustrate a strap with perforations being threaded through the tension buckle of FIG.  10 . 
     FIG. 12 is a perspective view of a second alternative embodiment of the tension buckles of the fastening system of FIG.  1 . 
     FIGS. 13 a-   13   c  illustrate a strap being threaded through the tension buckle of FIG.  12 . 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Preferred embodiments of the instant invention are directed to an apparatus and a method for fastening a water heater  9 , or the like, to the wall of a dwelling or other structure to increase safety in the building. With reference to FIG. 1, preferred embodiments of the fastening system  10  include a plurality of brackets  12 , tension buckles  14 , straps  16  and a spacer  18 . 
     With reference to FIG. 2 a , the brackets  12  include a top member  20  and a bottom member  22 . In some embodiments the brackets  12  further include at least one tooth  26  (FIGS. 2 b  and  2   d ). The top member  20  includes a planar member  28 , and a channel member  32 , wherein the planar member  28  includes a first end  30  and a second end  33  and wherein the channel member  32  is coupled to the first end  30  and extends along the width of the top member  20 . The planar member  28  further includes an aperture  34  capable of receiving a fastener, such as, for example, a screw or nail. In preferred embodiments, the aperture  34  is elongated in shape, such as, for example, oval, although any shape that is capable of allowing the passage of the fastener, e.g., a screw, in the open and closed position of the bracket  12  is suitable. With reference to FIG. 3 a , the planar member  28  is rectangular in shape, although other shapes, such as, for example, a square, may be suitable. 
     With reference to FIGS. 2 a-   2   c , the channel member  32  is shaped as an inverted U, although any shape of the channel member  32 , such as, for example, a rectangle, is suitable. The channel member  32  is coupled to the first end  30  of the planar member  28 , wherein the coupling between the channel member  32  and the first end  30  can be direct, as shown in FIG. 2 a , or with a U-shaped channel  38 , as shown in FIG. 2 c.    
     The bottom member  22  includes a first end  40 , a second end  42 , and legs  36 . An aperture  46  is formed by the space between the legs  36 . The first end  40  further includes a lip  48  which extends along the width of the bottom member  22  towards the top member  20 . The lip  48  is configured such that it is capable of being received within the channel member  32  of the top member  20  to form a lock. With reference to FIG. 3 b , the aperture  46  of the bottom member  22  is larger than the aperture  34  of the top member  20  and thus at least a portion of the aperture  46  aligns with the aperture  34  in the top member  20 . The aperture  46  is capable of receiving a fastener, e.g., a screw, and a restraining member  16 , e.g., a strap, which is further discussed below. However the aperture  46  must be sized such that it does not weaken the integrity of the bracket  12 . Typically, the aperture  46  is T-shaped, although any shape, such as, for example, a square or cross, which is capable of receiving both a coupling member and a restraining member in addition to maintaining the integrity of the bracket  12  is suitable. 
     Referring again to FIG. 2 a , the second end  33  of the planar member  28  couples to the second end  42  of the bottom member  22  via the legs  36  in a hinge-like manner. When the top member  20  and the bottom member  22  are coupled together, the first end  40  and the channel member  32  are outwardly biased with respect to each other. In some preferred embodiments, the top member  20  may be coupled to the bottom member  22  by a hinge. 
     With reference to FIGS. 2 b  and  2   d , the tooth  26  is a spike-like member having a triangular shape, wherein the apex of the triangle is configured to puncture through a supporting structure in the environment, such as, for example, a wall or stud. The tooth  26  is coupled to the bottom member  22  and extends perpendicular therefrom. Preferably, at least two teeth  26  are coupled to the bottom member  22 , although in some preferred embodiments, a single tooth  26  can be coupled to the bottom member  22 . The teeth  26  aid in securing the brackets  12  to the wall. 
     With reference to FIG. 4, the tension buckles  14  include an elongated member  54 , an arm  56  and flanges  58 . The elongated member  54  includes a first end  60 , a second end  62  and a plurality of apertures  64 , wherein the apertures  64  are disposed between the first and second ends  60 ,  62 . The arm  56  includes an aperture  55  and is coupled to the first end  60  of the elongated member  54 , wherein the arm  56  extends substantially perpendicularly therefrom such that an L-shape is formed upon coupling. In some preferred embodiments, the arm  56  and elongated member  54  are manufactured as a single piece. 
     The flanges  58  extend along both sides of the elongated member  54  and the arm  56  such that a channel  66  is formed. Some preferred embodiments do not include a flange  58 . Reference is further made to U.S. Pat. No. 5,487,518 to McCraney, which is incorporated herein by reference, wherein a preferred embodiment of the tension buckles  14  is described. 
     With reference again to FIG. 1, in one preferred embodiment, the straps  16  include a short strap  17  and a long strap  19 , wherein the short strap  17  and the long strap  19  each include a first end  68  and a second end  70 . Preferably, the short strap  17  and the long strap  19  are substantially identical in nature, for example, the same material and shape, except with respect to their respective lengths. Both the short strap  17  and the long strap  19  can vary in length depending upon the size of the water heater  9  and the placement of the heater  9 . Referring to FIGS. 5 a  and  5   b , the short strap  17  must be long enough to extend from the wall to the front of the water heater  9 . By contrast, the long strap  19  must be long enough to extend from the wall to the front of the water heater  9  and wind around the circumference of the water heater  9  for one turn so that it can meet the short strap. Preferably, the straps  16  are made from a malleable alloy, such as, for example, aluminum or sheet metal, although any material strong enough to maintain a water heater  9  in place (potentially during a disaster), such as, for example, leather, is suitable. 
     With reference to FIG. 6, the preferred embodiment of the spacer  18  includes a back member  72  including an aperture  73 , two legs  74  and flanges  75 , wherein the back member  72  and the legs  74  each include a top  77  and a bottom  79 . Each leg  74  includes an aperture  76  capable of receiving the long strap  19  and the legs are coupled to the back member  72 , wherein the legs  74  and the back member  72  are positioned such that the apertures  76  in each of the legs  74  are aligned. The flanges  75  are coupled to both, and extend perpendicularly from, the top  77  and the bottom  79  of the legs  74  and the back member  72 . In one preferred embodiment, the spacer  18  is mounted to the wall via the aperture  73 . In some preferred embodiments, the back member  72  does not include an aperture  73 . 
     With reference to FIGS. 1,  7   a  and  7   b , the assembly and installation of the fastening system for a preferred embodiment will now be described. In operation, the first end  68  of the short strap  17  is pulled between the lip  48  and the channel member  32  and threaded through the aperture  46  in the bottom member  22  of a bracket  12 . The short strap  17  is pulled through such that a portion of the short strap  17  can be pulled and folded underneath the bottom member  22 . The first end  68  portion of the strap  17  is folded underneath the bottom member  22  behind the water heater  9 . 
     After the short strap  17  is pulled through the bracket  12 , the bracket  12  is appropriately positioned near the water heater  9  and loosely attached to the supporting structure in the environment, e.g., the wall, with a fastener passing through the apertures  34  and  46  in the top member  20  and bottom member  22 , respectively, of the bracket  12  (see FIG. 2 a ). As the fastener is tightened, the top member  20  moves towards the bottom member  22  until the channel member  32  receives the lip  48 . The fastener is tightened until the channel  32  is locked over the lip  48  or until the top member  20  meets the bottom member  22 . Referring to FIG. 7 b , as the screw is tightened, the portion of the short strap  17  disposed between the channel member  32  and the lip  48  is pushed into the channel  32  and held in place by the lip  48 . 
     After securing the first bracket  12  to the wall, the short strap  17  is threaded into one of the tension buckles  14 . With reference to FIG.  4  and FIGS. 8 a-   8   c,  the second end  70  of the short strap  17  is threaded into (towards the water heater  9 ) the aperture  64  closest to the first end  60  of the elongated member  54  (FIG. 8 a ). The short strap  17  is then pulled out of (away from the water heater  9 ) the aperture  64  closest to the second end  62  of the elongated member  54  (FIG. 8 b ). The remaining portion of the short strap  17  is disposed within the channel  66  of the elongated member  54  (FIG. 8 c ). After the short strap  17  has been affixed at both ends, the long strap  19  is threaded into the second tension buckle  14  in the same manner as described above. Once both the short strap  17  and long strap  19  are threaded into their respective tension buckles  14 , but before the long strap  19  is wound around the water heater, the tension buckles  14  are positioned such that the arms  56  reside adjacent each other and face outward from the water heater  9 . A fastener, such as a nut and bolt, is then passed through the apertures  55  and secured such that the arms  56  of the tension buckles  14  are apart from each other. Depending upon the manner in which the strap  16  is being attached, the tension buckles  14  may be tightly secured by the this fastener such that a tautness results. In other instances, the tension buckles  14  are loosely secured until the long strap  19  is wound around the water heater and secured to the wall. 
     Once the straps  16  are threaded into the tension buckles  14 , the long strap  19  is then wound around the circumference of the water heater  9  (see FIGS. 5 a  and  5   b ). While the long strap  19  winds around the water heater, the long strap is threaded through the apertures  76  in each of the legs  74  of the spacer  18  (see FIG. 6) such that the back member  72  resides adjacent the wall and the legs  74  extend toward the water heater  9 , as shown in FIG.  1 . The spacer  18  is then slid along the long strap  19  to a position between the back of the water heater  9  and the supporting structure. In instances where the restraining device is retrofit ting an existing water heater, the spacer  18  can be slid behind the water heater without requiring that the spacer  18  be attached to the wall. However, in some preferred embodiments, the spacer  18  is attached to the wall via with a fastener, such as a screw, passing through the aperture  73  of the spacer  18 . As the long strap  19  completes its turn around the water heater  9 , it preferably passes either above or below the tension buckles  14 . 
     Next, the long strap  19  is threaded through a bracket  12 . The bracket  12  is slid to its mounting position on the side of the water heater opposite to the short strap, wherein a bolt or other securing member is passed through the apertures on the arms  56  of the tension buckle  14  and tightly secured. The straps  16  are then pulled until the straps  16  snugly surround the water heater  9 . 
     Points of adjustability with respect to the preferred embodiment include both the brackets  12  and the tension buckles  14 . Indeed, the water heater  9  can be secured by sliding the brackets  12  along any portion of either short strap  17  or long strap  19 , or by tightening the bolt securing the tension buckles  14  in front. The manner of adjustment is dictated, in part, by the environment in which the water heater is installed. For example, a tight corner may prohibit tightening of one of the brackets  12 . 
     Preferably, the water heater  9  is restrained in two locations, one location toward the upper end of the water heater and the other location toward the lower end. For instance, the water heater can be strapped within the upper one third of the water heater  9  and also strapped at a second location just above the heater controls, such as, for example, 4 inches above the heater controls. Double strapping will improve the stability of the water heater  9  with respect to shaking and rocking motions. This reduces motion during shaking and rocking, thereby minimizing the potential for the water heater to break away from the wall or break away from the gas lines. In either situation, the dwelling could suffer damage from fire, flood (due to the body of the water heater breaking) or both. 
     Other preferred embodiments do not include a long strap  19 , and thus, do not wrap a long strap  19  around the circumference of the water heater. Instead, another short strap  17  substitutes for the long strap  19 . With reference to FIG. 9 a , the straps  16  in this embodiment are attached in the same manner as described above for the attachment of the short strap  17 . All other applicable adjustments are made in the manner described above. With reference to FIG. 9 b , in another preferred embodiment, the fastening system does not include tension buckles  14  and only one strap  16  is used. In this embodiment, one end of the strap  16  includes an aperture  78  for directly bolting the strap to the wall stud. The manner of attachment to the bracket  12  is the same as described above. As such, in these embodiments, the brackets  12  are capable of restraining the water heater  9  as a solo feature. 
     Another embodiment for tension buckles  14  and straps  16  is shown in FIGS. 10 and 11 a-   11   c.  In this embodiment, the straps  16  have perforations  84  and the aperture  64  in the elongated member  54  of the tension buckle  14  contains a tab  80 . When the strap  16  is threaded through the aperture  64 , a selected perforation  84  is engaged by the tab  80  to prevent the strap  16  and tension buckle  14  from sliding with respect to each other. Assembly of the strap  16  to the tension buckle  14  is easier because it is no longer necessary to thread the strap  16  through a second aperture  64  of the tension buckle  14  (such as shown in FIGS. 5 a-   5   b ) to secure the strap  16 . 
     A further embodiment for tension buckles  14  is shown in FIGS. 12 and 13 a-   13   c.  In this embodiment, the aperture  64  in the elongated member  54 , contains a pointed tab  82 . While a tension buckle  14  with a pointed tab  82  can be used with a strap  16  with perforations  84 , the main advantage of the pointed tab design is that a non perforated strap can be utilized. During assembly, as the straps  16  are tightened, the pointed tab  82  will puncture its own hole in strap  16 , thereby obviating the need for a perforated strap, while maintaining the ease of installation advantage of the embodiment shown in FIG.  10 . 
     The above described preferred embodiments are not meant to limit the invention. Rather, all permutations of use of various features are intended. Thus, for example, use of a restraining device without a spacer  18 , but with a tension buckle  14  is also possible. 
     Although the foregoing describes the invention with preferred embodiments, this is not intended to limit the invention. Rather, the foregoing is intended to cover all modifications and alternative constructions falling within the spirit and scope of the invention.