Abstract:
In accordance with one embodiment of the present invention, a fastener holding bracket is provided. In some embodiments, the fastener holding bracket includes an attaching portion configured to attach the fastener holding bracket to a mounting tab; and a holding structure attached to the bracket configured to hold a fastener when the fastener is placed in the holding structure. In accordance with yet another embodiment of the present invention, a method of positioning a fastener with a mounting tab is provided. In some embodiments, the method includes aligning fastener holding structure on a fastener holding bracket to a hole on a mounting tab; and positing a fastener in the fastener holding structure.

Description:
FIELD OF THE INVENTION  
       [0001]     The present invention relates generally to a method and apparatus for holding a fastener in place so that the fastener may be installed. More particularly, the present invention relates to a bracket for supporting a fastener (such as a nail, screw or the like) in place so that the fastener may be installed in a mounting tab for mounting a box appliance such as a ventilation fan or light to a joist.  
       BACKGROUND OF THE INVENTION  
       [0002]     Many households and commercial appliances are installed by being fastened to ceiling joists in buildings. For example, bathroom ventilation fans, which may also include lights, are installed to a ceiling joist. The ventilation fan is often contained within a box housing. The box housing may be attached to a joist by a tab that either can be integral with the housing or connected to the housing.  
         [0003]     These boxes may be installed in a variety of ways; however, two ways are often used. In the first method, a fastener such as a nail or screw is partially driven into a specific place at a measured distance from one of the edges of the ceiling joist. A second fastener is then partially installed the same distance from the same edge of the joist and at a measured distance from the first fastener. The box or housing is installed by placing the large openings in keyhole slots located in the mounting tabs attached to the housing over the partially driven end fasteners and dropping the box housing into place, moving the fasteners along the slot portions of the keyhole slots. The fasteners are then tightened or driven to secure the box to the joist. While this method is effective, it requires time and accurate measuring to locate the fasteners in the proper place.  
         [0004]     In another common method of installing box appliances, the mounting holes in the mounting tab are used as a template. The installer positions the box against the side of a ceiling joist, and then marks on the joist using the mounting holes as a template to where locate the fasteners in the ceiling joist. The installer then removes the box from its place in the housing and partially installs the fasteners. Once the fasteners are partially installed where indicated on the ceiling joists, the installer then puts the box back into position placing the keyhole over the heads of the fasteners and dropping the box into place. Then the fasteners are completely driven into the joist to secure the box to the joist. Once the box is in place, additional fasteners may be used to secure the box or housing in place.  
         [0005]     One disadvantage of this method is that the installer must set the box down in order to preinstall the nails or screws. This can be cumbersome particularly in instances, which is often the case, where the installer is working on a ladder in a dimly lit area. Therefore, a method and apparatus that will more easily allow an installer to install a box to a ceiling joist is desired.  
         [0006]     Accordingly, it is desirable to provide a method and apparatus that provides a simple way for an installer to install a box appliance.  
       SUMMARY OF THE INVENTION  
       [0007]     The foregoing needs are met, to a great extent, by the present invention, wherein in one aspect, a method and apparatus is provided that in some embodiments a fastener securing bracket holds a fastener and locates it with respect to the mounting holes in the mounting tab so that an installer can easily install the box in a desired location along the joist.  
         [0008]     In accordance with one embodiment of the present invention, a fastener holding bracket is provided. In some embodiments, the fastener holding bracket includes an attaching portion configured to attach the fastener holding bracket to a mounting tab; and a holding structure attached to the bracket configured to hold a fastener when the fastener is placed in the holding structure.  
         [0009]     In accordance with another embodiment of the present invention, a fastener holding bracket is provided. In some embodiments, the fastener holding bracket includes means for attaching the fastener-holding bracket to a mounting tab; and means for holding a fastener aligned with a hole in a mounting tab.  
         [0010]     In accordance with yet another embodiment of the present invention, a method of positioning a fastener with a mounting tab is provided. In some embodiments, the method includes aligning fastener holding structure on a fastener holding bracket to a hole on a mounting tab; and positing a fastener in the fastener holding structure.  
         [0011]     There has thus been outlined, rather broadly, certain embodiments of the invention in order that the detailed description thereof herein may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional embodiments of the invention that will be described below and which will form the subject matter of the claims appended hereto.  
         [0012]     In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of embodiments in addition to those described and of being practiced and carried out in various ways. In addition, it is to be understood that the phraseology and terminology employed herein, as well as the abstract, are for the purpose of description and should not be regarded as limiting.  
         [0013]     As such, those skilled in the art will appreciate that the conception upon which this disclosure is based may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.  
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0014]      FIG. 1  is a perspective view illustrating a mounting system including a mounting tab and fastener holding bracket in an initial condition attached to a box housing in accordance with one embodiment of the invention.  
         [0015]      FIG. 2  is a perspective view illustrating a fastener being held by the fastener holding bracket in an intermediate position and the box housing butted up against the joist in a desired location.  
         [0016]      FIG. 3  is a perspective view of a box housing located against the joist in a desired location where two fasteners are held in place by two fastener holding brackets.  
         [0017]      FIG. 4  is a perspective view illustrating an installed box housing where the fastener holding bracket is in a final position.  
         [0018]      FIG. 5  is a perspective view of an alternate embodiment according to the invention where the holding bracket is separate from the mounting tab.  
         [0019]      FIG. 6  is a cross-sectional view taken along the line  6 - 6  of  FIG. 5 . 
     
    
     DETAILED DESCRIPTION  
       [0020]     The invention will now be described with reference to the drawing figures, in which like reference numerals refer to like parts throughout. An embodiment in accordance with the present invention provides an apparatus for holding a fastener for mounting a boxed appliance such as a bathroom ventilation fan. Another embodiment, in accordance with the present invention, provides a method of holding a fastener in place for fastening an appliance such as a ventilation fan to a ceiling joist.  
         [0021]     An embodiment of the present inventive apparatus is illustrated in  FIG. 1 . A mounting system  10  is mounted to a box  12 . The box  12  includes an outer housing  14 . Contained within the housing  14  is an appliance such as a ventilation fan or ventilation fan light combination. In other embodiments of the invention, other box housings may include other objects other than ventilation fans and ventilation fan light combinations.  
         [0022]     The mounting system  10  includes a mounting tab  16 . The mounting tab  16  may be integral to the housing  14  or may be attached to the housing  14 . Attached to, and in some embodiments integral with, the mounting tab  16 , is a fastener holding bracket  18 . The mounting tab  16  includes mounting holes  20 . The mounting holes  20  extend through the mounting tab  16  and are configured to permit fasteners to extend through the mounting holes  20  to fasten the mounting tabs  16  to a joist  24  (see for example,  FIG. 2 ).  
         [0023]     In some embodiments of the invention, a keyhole slot  22  is found in the mounting tab  16 . The keyhole slot  22  permits the head of a fastener such as a nail or screw to pass through a large portion of the keyhole slot  22  and allow the narrow portion of the keyhole slot  22  to slide along a shaft portion of a fastener and allow the fastener to secure the mounting tab  16  to the joist  24 .  
         [0024]     The fastener holding bracket  18  may include fastener holding holes  26 . The fastener holding holes  26  may be dimensioned so that they provide a press fit for a fastener that is placed in the fastener holding holes  26  in order to hold a fastener snug in the holes  26 .  
         [0025]     In addition, the fastener holding bracket  18  may also include fastener holding slits  28 . In some embodiments of the invention, the fastener holding slits  28  are elongated slits that cross in an X shape as shown in  FIG. 1 . Optionally, a fastener holding opening  30  may appear where two fastener holding slits  28  intersect. A structure including fastener holding slits  28  and a fastener holding opening  30  may be useful to adapt to whatever size fastener will be used for securing the box  12  to a joist  24 . Thus, the fastener holding slits  28  and fastener holding openings  30  are. adaptable for fasteners of various diameters.  
         [0026]     In embodiments of the invention where the fastener holding bracket  18  is part of, or integral to, the mounting tab  16 , as shown in  FIG. 1 , a flexing slot  32  may be found. The flexing slot  32  helps define a border between the mounting tab  16  and the fastener holding bracket  18 . One purpose of the flexing slot  32  is to weaken the fastener holding bracket  18  and mounting tab  16  combination to facilitate bending of the fastener holding bracket  18  toward the mounting tab  16 , as shown in  FIGS. 2-4 .  
         [0027]     With the absence of material in the flexing slot  32 , the remaining material present forms hinge portions  34 . In embodiments of the invention equipped with hinge portion  34 , the hinge portions  34  are considered attaching portions configured to attach the fastener mounting bracket  18  to the mounting tab  16 . It is anticipated that the hinge portions  34  will be flexed when the fastener holding bracket  18  is bent over across the mounting tab  16 , as shown in  FIGS. 2-4 . The flexing slot  32  also aids an installer to know where to bend the mounting system  10 .  
         [0028]     Turning now to  FIG. 2 , a box  12  is placed in the desired position against a ceiling joist  24  for mounting. The fastener holding bracket  18  is bent across the mounting tab  16 . Often this is done so that the fastener holding bracket  18  and the mounting tab  16  are within about a 45-60 degree angle with respect to each other. The fastener holding holes  26  on the fastener holding tab  18  are somewhat aligned with the mounting holes  20  on the mounting tab  16 .  
         [0029]     In some embodiments of the invention, and as shown in the figures, the fastener holding slits  28  and the fastener holding opening  30  may be somewhat aligned with the keyhole slot  22  located on the mounting tab  16 . The fastener  36  is placed in the fastener holding opening  30  and fastener holding slits  38  and extend through the fastener holding opening  30  and fastener holding slits  28  and extended through the keyhole slot  22  so that the tip of the fastener  36  is in contact with the joist  24 . In other embodiments of the invention, fasteners  36  can extend through the fastener holding holes  26  and the mounting holes  20  so that the tip of the fastener  36  is in contact with the joist  24 .  
         [0030]     In some embodiments of the invention, and as shown in  FIG. 3 , a box  12  may be attached to several mounting tabs  16  with fastener locating tabs  18  for securing the box  12  to the joist  24 . The fasteners  36  are held in place by the fastener holding brackets  18 . The fasteners  36  can be driven into the joist  24  with a hammer in the case of the fastener  36  being a nail or with a screwdriver or any other any appropriate fastener driving tool, depending on what type of fastener is used.  
         [0031]      FIG. 4  shows a fastener  36  driven into the joist  24 . When the fastener  36  is driven fully into the joist  24 , the fastener holding bracket  18  is bent over to lay adjacent to the mounting tab  16 . In some embodiments of the invention, a face  37  of the fastener holding bracket  18  may contact a face  39  of the mounting tab  16  when the fastener  36  is fully driven into the joist  24 .  
         [0032]     One advantage of some embodiments of the invention is that with the fastener  36  securing both the fastener locating tab  18  and the mounting tab  16  to the joist  24 , as shown in  FIG. 4 , the box  12  may be more securely fastened to the joist  24 . The combined thicknesses of the fastener holding bracket  18  and the mounting tab  16  are thicker than a mounting tab  16  being alone fastened to the joist  24 .  
         [0033]     Another embodiment of the invention is shown in  FIGS. 5 and 6 . In the embodiments shown in  FIGS. 5 and 6 , the fastener mounting bracket  18  is not integral to the mounting tab  16 , but is rather a separate piece and attaches to a mounting tab. The separate attachable fastener mounting bracket  18  may be useful for holding fasteners  36  to mounting tab  16  that are not equipped with a fastener holding bracket  18 .  
         [0034]     The fastener holding bracket  18 , shown in  FIG. 5 , includes fastener holding holes  26 , fastener holding slits  28 , which intersect each other in a X-shape, and a fastener holding opening  30 . The fastener holding bracket  18  also includes a slip on portion  38  for engaging and holding the fastener holding tab  18  to a mounting tab  16 . In embodiments housing a slip on portion  38 , the slip on portion  38  is an attaching portion configured to attach the fastener holding bracket  18  to the mounting tab  16 .  
         [0035]     The fastener holding bracket  18 , of  FIG. 5 , includes a flexing region  40 . The flexing region  40  is located between the slip on portion  38  and the flat faced portion  42 . The flat faced portion  42  includes the fastener holding holes  26  and the fastener holding slits  28  and the fastener holding opening  30 . The flexing region  40  operates in a similar manner as described above for permitting the fastener holding bracket  18  to flex and bend toward the mounting tab  16  when a fastener is being installed to a joist  24 .  
         [0036]     Some embodiments of the invention may include a flexing slot  32  located in the flexing region  40  located and configured similarly to the flexing slot  32  described with respect to the embodiment described with respect to  FIGS. 14 .  
         [0037]      FIG. 6  is a cross section of the fastener holding bracket  18 , illustrated in  FIG. 5 , taken along the line  6 - 6 . It is a cross section of the slip on portion  38 . As shown in  FIG. 6 , the slip on portion  38  includes engaging channels  44 , which are defined, at least in part, by the C-shaped sections  46 . A user using a fastener holding bracket  18  of  FIGS. 5 and 6  will use the slip on portion  38  to attach the fastener holding bracket  18  to a mounting tab  16 . The mounting tab  16  will be inserted into the engaging channels  44  so that the fastener holding bracket  18  is in a press fit engagement with the mounting tab  16 .  
         [0038]     If the C-shaped sections  46  need to be flexed or bent to facilitate a tight hold of the fastener holding bracket  18  on to the mounting tab  16 , a user can accomplish this by bending or flexing the C-shaped sections  46 . The mounting tabs  16  will be inserted into the engaging channels  44  until the fastener holding holes  26  or fastener holding slits  28  and fastener holding opening  30  are somewhat aligned with the mounting holes  20  or keyhole slot  22  located in a mounting tab  16 .  
         [0039]     The flat face  42  section and the slip on portion  38  can be manufactured so that they are at an obtuse angle with respect to each other as shown in  FIG. 5 . In other embodiments of the invention, the slip on portion  38  and the flat face region  42  are initially substantially coplanar. In either event, a user can bend the slip on portion  38  along the flexing region  40  to achieve a desired angle between the slip on portion  38  and the flat face region  42 . This bending can be done either before or after the mounting tab  16  has been inserted into the engaging channels  44 , depending on the judgment of a user of the mounting system  10 .  
         [0040]     Once the fastener locating tab  18  has been flexed so that the slip on portion  38  and the flat face region  42  are at desired angles with respect to each other, and the mounting tab  16  has been inserted into the engaging channels  44  to a point where there is alignment between the fastener holding holes  26  and the mounting holes  20  or the fastener locating slots  28  the fastener holding opening  30  and a keyhole slot  22 , a fastener  26  can be inserted into either the fastener holding holes  26  and extend into the mounting holes  20  and but up against a joist  24 .  
         [0041]     Alternatively, a fastener  26  can be inserted into the fastener holding opening  30 , fastener holding slits  28  and extend into a keyhole slot  22  and but up against a joist  24 . The fastener  36  can then be driven into the joist  24 . The act of driving the fastener  36  into the joist  24  will cause additional flexing in the flexing region  40  similar to what which is described above with respect to  FIG. 4 .  
         [0042]     It will be appreciated by one skilled in the art that as the face of the fastener holding bracket  37  approaches and eventually, in some embodiments, contacts the face of the mounting tab  39  that the fastener locating holding holes  26  become more and more aligned with the mounting holes  20 . In addition, the fastener holding slits  28  and fastener holding opening  30  will become more and more aligned with the keyhole slot  22 . These holes will become further aligned with respect to each other as the fastener  36  is driven further into the joist  24 . The fact that these holes become further aligned as the fastener holding bracket  37  moves toward the mounting tab  39  is why the initial condition where the fastener is first installed these holes is described as somewhat aligned.  
         [0043]     The somewhat alignment term is intended to describe the holes being aligned with respect to each other enough so that a fastener  36  can extend through fastener holding holes  26  into the mounting holes  20  and against the joist  24  and be driven into the joist  24 . Once the fastener  36  is fully driven into the joist  24 , the fastener  36  and fastener holding bracket  18  will be at or near a position where the face of the mounting tab  39  contacts or is in close proximity to the face of the fastener holding bracket  37 , as shown in  FIG. 4 .  
         [0044]     According to some embodiments of the invention, the fastener holding bracket  18  and/or the mounting tab  16  may be made of a variety of suitable materials. Examples of suitable materials include metal and plastic. In other embodiments of the invention, other suitable materials may be used.  
         [0045]     Although an example of the mounting system  10  is shown in the context of a box appliance such as a ventilation fan, it will be appreciated it can be used other contexts. Also, although the mounting system  10  is useful to mount objects to joists, it can also be used in other contexts.  
         [0046]     The many features and advantages of the invention are apparent from the detailed specification, and thus, it is intended by the appended claims to cover all such features and advantages of the invention which fall within the true spirit and scope of the invention. Further, since numerous modifications and variations will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation illustrated and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.