Abstract:
Kits and/or methods for mounting a flat panel display are disclosed. A kit includes a wall plate, a pair of mounting rails, and a pair of tilt-adjustable mounting brackets for connecting the mounting rails with the wall plate. The wall plate includes an upper horizontal mounting edge. Each of the mounting rails includes a bottom surface having apertures to attach the mounting rail with the flat panel display, and two side surfaces perpendicular to the bottom surface. The two side surfaces include holes configured to receive and support each of a pair of tilt adjustment mechanisms. Each of the mounting brackets includes an upper-end hook, a lower-end safety fastener, and two non-parallel tilt adjustment slots, each slot dimensioned to receive a tilt adjustment mechanism. The tilt adjustment slots accommodate the tilt adjustment mechanisms through a range of tilt angles between the flat panel display and the wall plate.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    The present invention relates to systems for mounting a flat panel display to a wall, a ceiling, or other structure. In particular, the present invention provides a system capable of securely attaching a display of varying sizes and adjusting the tilt angle of the display. 
         [0002]    Flat panel displays are becoming increasingly popular as computer monitors and TV sets. The popularity of flat panel displays has led to the use of the displays in many sizes and in many locations, from family rooms to conference rooms. The flat panel displays are typically mounted on floor stands, housed in a dedicated piece of furniture, or attached to the walls or ceilings. The floor space taken by the floor stands and the furniture makes those options less attractive. The available wall and ceiling mounting systems do not require floor space, but they lack the ability to adjust the flat panel&#39;s tilt angle while securely holding flat displays, which may come in a wide variety of sizes. Some of the flat panel displays are very heavy, and they have to be attached to wall or ceiling studs. The available wall and ceiling mount systems often lack the ability to conveniently locate studs and place mounting indicia on the surfaces. If the mounting system is not installed properly, it could fall off the mounting surface. 
         [0003]    Furthermore, since flat panel displays come in a variety of sizes, it is impractical to have a different mounting system for each flat panel display size. The wall or ceiling mounting systems are usually positioned away from the power and signal cable receptacles, thus requiring dedicated cable management systems. 
         [0004]    Thus, there exists a need for flat panel display mounting systems that do not suffer from the above shortcomings. 
       BRIEF SUMMARY OF THE INVENTION 
       [0005]    The present invention provides a system for mounting a flat panel display to a wall, a ceiling, or other structure. The system for mounting a flat panel display can provide a secure attachment for a wide variety of flat panel display sizes. The flat panel display is tiltable within a range of angles for a better viewing experience. The system can have a template for the placement of the mounting indicia on the wall and a cable cover for securing the cables running to the flat panel display. 
         [0006]    In one embodiment, a flat panel display mounting kit includes: a wall plate configured to be attached with a mounting surface, the wall plate having a substantially horizontal mounting edge disposed on the upper side of the wall plate; a pair of mounting rails configured to be attached with a flat panel display, each mounting rail having a bottom surface and two side surfaces substantially perpendicular to the bottom surface, the bottom surface having a plurality of apertures to attach the mounting rails with the flat panel display, the side surfaces each having two apertures to receive a tilt adjustment mechanism; a pair of tilt-adjustable mounting brackets configured to connect the mounting rails with the wall plate, each tilt-adjustable mounting bracket having an upper side and a lower side opposite the upper side, each tilt-adjustable mounting bracket having a hook disposed on the upper side configured to releasably attach to the mounting edge on the wall plate and a safety fastener disposed on the lower side configured to releasably press against the wall plate; and two non-parallel tilt adjustment slots dimensioned to receive the tilt adjustment mechanism which is positioned to slidably mate with the corresponding apertures on the side surfaces of the mounting rail. 
         [0007]    In one aspect, the flat panel display mounting kit also includes a mounting template guide configured to be releasably attached to the mounting surface, the mounting template guide having a plurality of adhesive strips on one side and a plurality of alignment apertures used to mark the alignment indicia on the mounting surface, the alignment indicia being used for the placement of the wall plate. 
         [0008]    In another aspect, the flat panel display mounting kit also includes a cable cover back plate and a cable cover front plate having a configurable length, the cable cover plates being disposable beneath the wall plate and attachable to the mounting surface. 
         [0009]    In yet another aspect, the tilt adjustment mechanism has a tilt adjustment knob configured to be hand-releasably inserted through apertures on the side surfaces of a mounting rail and a corresponding mating slot on a mounting bracket, and a tilt adjustment fastener configured to be inserted through apertures on the side surfaces of a mounting rail and a corresponding mating slot on a mounting bracket. 
         [0010]    In yet another aspect, the wall plate has a plurality of mounting holes shaped substantially as horizontal slots for the ease of alignment over the mounting surface. 
         [0011]    For a further understanding of the nature and advantages of the invention, reference should be made to the following description taken in conjunction with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the embodiments of the present invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]      FIGS. 1A and 1B  show perspective views of the flat panel mounting kit in accordance with one embodiment of the present invention.  FIGS. 1A and 1B  show the kit prior and after the attachment of the tilt-adjustable mounting bracket with the wall plate, respectively. 
           [0013]      FIG. 1C  shows the attachment of the mounting rails to a flat panel display. 
           [0014]      FIGS. 2A-2B  illustrate exploded views showing the mounting rail, tilt adjustable mounting bracket, tilt adjustment knob, and tilt adjustment fastener in accordance with one embodiment of the present invention. 
           [0015]      FIG. 3  shows several views of the flat panel mounting kit in accordance with one embodiment of the present invention. The side views shown in the details A-D illustrate one embodiment of a tilt adjustment range. 
           [0016]      FIG. 3A  shows another embodiment of the tilt adjustment range. 
           [0017]      FIG. 4  shows a mounting template guide in accordance with one embodiment of the present invention. 
           [0018]      FIG. 5  shows a cable cover in accordance with one embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0019]    The embodiments of the present invention are directed toward systems for mounting of flat panel displays, which are typically TVs or computer monitors, on a mounting surface, which can be a wall or a ceiling of a room, or some other surface. The advantages of mounting a flat panel display on the mounting surface are numerous. For example, no dedicated piece of furniture is needed to house a flat panel display. Furthermore, the choice of the exact location of the flat panel display is bigger with the present invention than with a dedicated piece of furniture. 
         [0020]    The details of an exemplary embodiment of the present invention are explained with reference to  FIGS. 1A-5 . The exemplary embodiment is described with reference to the mounting of the flat panel display on a vertical wall, but it will be clear to a person skilled in the art that the described system can also be used on a non-vertical walls. 
         [0021]      FIGS. 1A and 1B  show perspective views of a flat panel display mounting kit  100  in accordance with one embodiment of the present invention.  FIG. 1A  shows the kit with tilt-adjustable mounting bracket  3  prior to its attachment with wall plate  1 , while  FIG. 1B  shows kit  100  with tilt-adjustable mounting bracket  3  (hereinafter bracket) after its attachment with wall plate  1 . 
         [0022]    Flat panel display mounting kit  100  has wall plate  1  for attaching the kit with the mounting surface using a plurality of fasteners (not shown). The wall plate has two rows of apertures  12  distributed over the upper and lower regions of the wall plate for attaching the plate with the mounting surface. Apertures  12  are horizontally slotted for ease of alignment with the indicia on the wall (not shown). Other aperture shapes are also possible. The wall plate has connecting panel  14  to provide structural integrity to the wall plate, while minimizing the weight.  FIGS. 1A and 1B  show an approximately X-shaped connecting panel, but other shapes that minimize the weight of the wall plate while providing structural integrity needed to securely hold the flat panel display are also possible. For instance, the weight of the wall plate may be reduced by stamping or drilling an initially solid connecting panel. The removed areas may be arcuate, as shown in  FIGS. 1A and 1B , but may also be rectilinear or have some other shape. The wall plate can be made of powder coated steel or other suitable material. 
         [0023]    Wall plate  1  has mounting edge  11  on the upper side of the wall plate. Bracket  3  has hook  32  that is dimensioned to releasably attach with mounting edge  11 . The distance between the two brackets, as well as their location along the mounting edge, is adjustable. Bracket  3  also has safety fastener  37  disposed on the side opposite from hook  32 . The rotation of safety fastener  37  will cause it to come in contact with the wall plate, thus securing hook  32  in the contact with mounting edge  11 . The contact between safety fastener  37  and wall plate  1  also prevents bracket  3  from sliding along mounting edge  11 . The contact also prevents the bracket from rocking about the mounting edge. Bracket  3  can be arcuatelly shaped for easier attachment of hook  32  with mounting edge  11 , and also for easier contact of safety fastener  37  with the wall plate. Bracket  3  can be made of anodized aluminum or other suitable material. 
         [0024]    When the system is assembled, bracket  3 , which is connected to wall plate  1 , is also connected to mounting rail  2 . Back of the flat panel display (not shown) attaches with bottom surfaces  21  of mounting rails  2 . A plurality of flat panel mounting holes  23  are disposed on bottom surface  21  of the mounting rail. Some of the holes may be slotted with different slot lengths for the ease of alignment with the mating holes on the back of the flat panel display. 
         [0025]      FIG. 1C  shows the attachment of flat panel display  4  with mounting rail  2 . Bottom surface  21  of mounting rail  2  can be positioned over the mounting holes on the back of the flat panel. The alignment of flat panel mounting holes  23 , which are disposed on mounting rail  4 , and the mating holes on flat panel display  4  is made easier because flat panel mounting holes  23  are slotted. Once proper alignment is achieved, mounting rail  2  is secured to flat panel display  4  by suitable display mounting hardware  42 , which may be provided with the flat panel display mounting kit  100 . The flat panel, the mounting rails, and the brackets can now be attached to the wall plate by attaching hook  32  of the bracket to mounting edge  11  of the wall plate, and by securing safety fastener  37  against the wall plate. 
         [0026]      FIGS. 2A-2B  show further details of the engagement between bracket  3  and mounting rail  2 . Bracket  3  can be inserted between two side surfaces  22  on the mounting rail. Bracket  3  has a pair of tilt adjustment slots  34  which are disposed such that each can be aligned against a pair of tilt adjustment holes  24  on the opposite side surfaces of the mounting rail. Due to the non-parallel disposition of tilt adjustment slots  34 , the tilt angle which mounting rail  2  forms with bracket  3  changes as the tilt adjustment slots are slid along the tilt adjustment holes. 
         [0027]      FIGS. 2A-2B  also show tilt adjustment fastener  36  and tilt adjustment knob  35 , which can be inserted through the pairs of tilt adjustment holes  24  on the mounting rail and tilt adjustment slot  34  on the bracket. The tilt adjustment fastener and the tilt adjustment knob can be securely fastened. The tilt adjustment holes which are disposed opposite from each other on the two side surfaces  22  may have different shapes, for instance one being substantially circular, the other non-circular. The noncircular hole can be keyed to engage with neck  38  on the tilt adjustment fastener or the tilt adjustment knob. The keying prevents the tilt adjustment fastener and the tilt adjustment knob from spinning inside the tilt adjustment holes. In some embodiments, the substantially circular holes that receive tilt adjustment knob  35  can be placed on the outer surfaces  22  of the mounting rails, thus providing easier tilt angle adjustment, because the tilt adjustment knob can be loosened and tightened by hand. A square neck and a corresponding square hole on the side surfaces are shown in  FIG. 2 , but many other keying shapes are also possible. The non-circular holes are shown on the opposite side surfaces of the mounting rail, but they can also be disposed on the same side surface of the mounting rail. 
         [0028]      FIG. 3  shows several views of wall plate  1 , mounting rail  2 , and bracket  3  assembly. Details A-D of  FIG. 3  show the side planar views of the different engagement positions between mounting rail  2  and bracket  3 . Different tilt angles may be achieved by positioning tilt adjustment holes  24  along tilt adjustment slots  34 . Detail A shows an engagement position of mounting rail  2  and bracket  3  where tilt adjustment holes  24  on the mounting rail are in their upmost location relative to tilt adjustment slots  34  on the mounting bracket. In one embodiment this would cause the bottom surface of the mounting rail to form an approximately 15° downward angle. Detail B shows an opposite tilt angle range for the same embodiment, which is about a 5° upward angle, and may be achieved by positioning the tilt adjustment holes at the bottom of the tilt adjustment slots. Details C and D show side planar views of the opposite pair of the bracket and the mounting rail. The above range of tilting angles is typically sufficient for a pleasant viewing experience which eliminates glare and reflection from the flat panel display. A change to the available range of angles can be made by, for example, changing the length of the slots, the distance between the slots, and the angle between the slots. For example,  FIG. 3A  shows side planar views of another engagement position between mounting rail  2  and bracket  3  having the available range of angles between approximately 15° downward angle and 3° upward angle. 
         [0029]      FIG. 4  shows mounting template guide  5 , which can be used to place mounting indicia on the mounting surface. Mounting template guide  5  may be used to draw mounting indicia on the wall (not shown). The mounting indicia can be placed at the location of the wood studs or at the desired locations on solid concrete, block concrete, brick, or other masonry type wall. Mounting template guide  5  can have adhesive strips  51  which can be used for securing with the mounting surface. Mounting template guide  5  can also have a center mark  52 , which can be used to place a center indicia on the mounting surface using a push pin or other sharp object. If the mounting surface has wood studs, they can be identified using a stud detector, and the mounting indicia can be placed over the studs through the slotted holes  53  on the mounting template guide. Locating lines  54  can be used to locate the wood studs if the offset from one stud to another is known a priori. The mounting indicia are visible through center hole  13  and mounting holes  12  on wall plate  1 , and can be used to locate the holes for the attachment of the wall plate over the mounting surface. 
         [0030]      FIG. 5  shows cable cover  6  having cable cover back plate  61  and cable cover front plate  62 . When mated against each other, the cable cover back and front plates form a conduit that can be used to dispose the cables therein. The cable cover may be disposed beneath the wall plate such that it houses and protects the flat panel display cables. Cable cover  6  can be cut and configured to a desired length, as shown in Detail A of  FIG. 5 . Cable cover  6  may be attached to the mounting surface using one or more fasteners. 
         [0031]    As will be understood by those skilled in the art, the present invention may be embodied in other specific forms without departing from the essential characteristics thereof. For example, the embodiments with three or more mounting rails are possible for the flat panel displays which are heavy or large. The tilt adjustment holes on the side surfaces of the mounting rails may be all made non-circular and the fasteners may be of a hand-tightening type. Many other embodiments are possible without deviating from the spirit and scope of the invention. These other embodiments are intended to be included within the scope of the present invention, which is set forth in the following claims.