Abstract:
A device for supporting an article on a structure. The support device includes an elongate body with a head at one end, a neck, a shoulder flange, and an elongate threaded shank with threads extending therefrom. The head and/or neck may be arranged to engage the article, and the shoulder flange has a surface for engaging a corresponding surface of the structure. The elongate shank portion anchors the support device at a target site on the structure and tapers from a greatest diameter proximate to the shoulder flange to a pointed end. The initial taper is at a lesser angle to the longitudinal axis of the elongate body to a point where the angle increases, before which the threads may terminate.

Description:
REFERENCE TO CO-PENDING APPLICATIONS 
   The entire subject matter of U.S. Provisional application Ser. No. 60/626,776 filed Nov. 10, 2004 and entitled SUPPORTING DEVICE is incorporated by reference. The applicant claims priority benefit under Title 35, United States Code, Section 119(e) of U.S. Provisional application Ser. No. 60/626,776 filed Nov. 10, 2004 and entitled SUPPORTING DEVICE 
   The applicant claims priority benefit under Title 35, United States Code, Section 119 of Canadian application serial number 2,484,381 filed Oct. 8, 2004 and entitled SUPPORTING DEVICE. 

   TECHNICAL FIELD 
   The invention relates to a supporting device and is especially applicable to a supporting device for supporting an article from a support structure. 
   BACKGROUND ART 
   Anchors have become increasingly popular for mounting objects where screws, nails, adhesives or other simple fasteners are either impractical or ineffective. 
   A problem with anchors is that they are difficult to install, which is particularly problematic for individuals who do not have the skills or tools for performing difficult installations. Moreover, many anchors on the market are instable and do not adequately support heavy loads, especially in dry wall. In addition, they may also loosen over time, causing damage to the support structure on which they are mounted. 
   SUMMARY OF THE INVENTION 
   The present invention seeks to eliminate, or at least mitigate, the disadvantages of the prior art, or at least provide an alternative. 
   According to one aspect, the present invention provides a support device for supporting an article on a structure, the support device comprising an elongate body having a support head portion located at one end thereof, the support head portion including a head and a shoulder flange, the head and shoulder flange being separated by a neck, the head and/or neck being arranged to engage the article, the shoulder flange having a surface for engaging a corresponding surface of the structure, the elongate body further comprising an elongate shank portion for anchoring the support device at a target site on the structure. 
   In an embodiment, the support head has a three dimensional polygonal shape. 
   In a further embodiment, the support head has a three dimensional spherical shape. 
   In an embodiment, the support head further includes one or more than one recess for receiving a torque tool for installing the support device at the target site on the structure. The head of the support head portion includes a recess extending therein for engaging an installation tool. The recess has a slot, cruciform, star, rectangular or square shaped or a combination thereof. 
   In a preferred embodiment, the support head portion has a transverse passage located in the neck extending therethrough, to accommodate a torque tool. Preferably, the transverse passage is located in the neck. 
   In an embodiment, the installation tool includes a distal end for engaging the transverse passage and is preferably arranged to be hand held. 
   In an embodiment, the support device further comprises a support accessory engageable with the support head portion and being arranged to support the article at a location proximal or distal to the support head. The support accessory includes an anchor formation for engaging the neck and a support formation spaced from the anchor formation and including the support surface. In one example, the anchor formation includes a hook portion, but can be or include other arrangements or shapes as desired. 
   In a further embodiment, the elongate shank is screw threaded having a proximal end adjacent the support end and a distal end, and the shank portion decreases in cross-section from the proximal end to the distal end. 
   In an embodiment, the shank portion is adapted for insertion into the target site of the structure, the structure material including wood, plastic, fiberglass, paper, drywall, gypsum, cardboard, concrete, brick, steel or a combination thereof. 
   In an embodiment, the support head portion includes indicia of a pre-determined design theme. 
   In an embodiment, the indicia of a pre-determined design theme is on a paper, or a metal substrate attached to the support head portion. 
   In an embodiment, the indicia of a pre-determined design theme is in the form of an insignia insert. 
   In an embodiment, pre-determined design theme is on a removable cap positioned over the head portion of the support head. 
   In a further embodiment, the support head portion includes a relatively smooth, rough and/or textured outer surface. 
   In a further embodiment, the support device is made of a material having sufficient strength to support the weight bearing load of at least one kilogram in weight. 
   In an embodiment, the material of the support device is made of a plastic. 
   In a preferred embodiment, the material of the support device is made of a metal. 
   According to a further aspect, the present invention provides kit comprising a support device and a torque tool for anchoring the support device into a target site of a structure, the support device including an elongate body having an axially aligned support head portion located at one end of the body, the support head portion including a head, a neck extending away from the head and towards a shoulder flange integrally operable with the head and/or neck to support a weight bearing load; and an elongate shank portion integrally formed with the shoulder flange for anchoring the support device into a target site of the structure, the shank portion projecting away from the support head portion and integrally formed therewith to secure the support device in the target site. 
   In an even further aspect, the present invention provides a mold for use in the manufacture of one or more than one support device, said support device comprising the support device including an elongate body having an axially aligned support head portion located at one end of the body, the support head portion including a head, a neck extending away from the head and towards a shoulder flange integrally operable with the head and/or neck to support a weight bearing load; and an elongate shank portion at another end of the body and integrally formed with the shoulder flange for anchoring the support device into a target site of the structure, the shank portion projecting away from the support head portion and integrally formed therewith to secure the support device in the target site. 
   In still a further aspect, the present invention provides a method of supporting an article on a structure, comprising the steps of providing a support unit with an elongate body having a support head portion located at one end thereof, providing the support head portion with a head and a shoulder flange, the head and shoulder flange being separated by a neck, installing the support unit into the structure with the shoulder flange engaging an outer surface of the structure, with the neck and head exposed from the structure, and orienting the article so that a portion thereof engages the neck and/or the head. 
   In one embodiment of the method, the structure is a wall. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIGS. 1   a ,  1   b ,  1   c , are sectional, perspective and side views of a support device; 
       FIGS. 2   a ,  2   b ,  2   c ,  2   d ,  2   e ,  2   f  and  2   g  are sectional, side and perspective views of another support device and support accessory with a torque tool; 
       FIGS. 3   a  and  3   b  are sectional and side views of another support device; 
       FIGS. 4   a  and  4   b  are sectional, side and perspective views of still another support device; 
       FIGS. 5 through 14  are views of still other support devices; 
       FIGS. 15 and 16 , are perspective views of further support devices with an engaging recess in each head of the device; 
       FIGS. 17 ,  17   a ,  18  and  18   a  are plan views of heads of further support devices; 
       FIGS. 19   a ,  19   b ,  19   c  and  19   d , are perspective and sectional views of another support device receiving an indicia of a pre-determined design theme is in the form of an insignia insert cap thereon; and 
       FIGS. 20 and 21  are fragmentary perspective and plan views of a mold and a blank therefrom. 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   Referring to the figures, particularly  FIGS. 1   a  to  1   c , there is shown a support device  10  for supporting an article (such as, for example, a picture frame, not shown) on a structure, for example a wall  12 . The support device  10  has an elongate one piece body  14  having a support head portion  16  located at one end thereof. The support head portion  16  includes a head  18  and a shoulder flange  20  which are separated by a neck  22 . 
   As will be described, the head  18  and/or neck  22  are arranged to engage the article while the shoulder flange  20  has a surface  20   a  for engaging a corresponding surface of the structure. 
   The elongate body  14  has an elongate shank portion  24  for anchoring the support device at a target site on the structure. The elongate shank portion is, in this example, screw threaded with a proximal end  24   a  adjacent the shoulder flange  20  and a distal end  24   b , and the shank portion  24  decreases in cross-section from the proximal end to the distal end  24   b.    
   Preferably, the elongate shank portion  24  has a helical thread  26  extending along its surface. The thread  26  has two surfaces  26   a ,  26   b  extending along its length which converge toward one another to form an edge  26   c . The height of the thread, which is measured from a point on the edge to an adjacent point on the surface of the shank, diminishes progressively from an end of the thread adjacent to the support head portion to an end of the thread adjacent to the tip of the shank. Other thread configurations may be used as desired. 
   Of course, the elongate shank portion  24  may be of other configurations, as desired. Desirably, the elongate shank portion  24  is adapted for insertion into the target site of the structure  12 , which may include wood, plastic, and paper, cardboard, concrete, brick, steel or a combination of those materials. The support device  10  is also desirably made of a material with sufficient strength to support the weight bearing load of at least one kilogram in weight, though other weights may also be suitable, as desired. A most preferred form of material for the support device  10  is metal, such as alloys of aluminum, copper, steel magnesium, and zinc. 
   The support head  16 , in this case, has a polygonal shape in three dimensions. The support head  16  the support head is provided with a curved outer upper surface  16   a  to form a “button head” and is further provided with one or more than one recess for receiving a torque tool, such as a screw driver, a knife or the like (not shown), for installing the support device  10  at the target site on the structure  12 . In this case, the recess  28  for engagement of the installation tool  36  may be slotted as shown but may be of other shapes. For instance, the recess may be in the form of a cruciform, star, rectangular or square shape or a combination thereof as shown in  FIGS. 15  through to  18   a.    
   The support head may have a slotted upper surface  16   a  when viewed in cross section (as shown in  FIG. 1   a ), but may also be flat if desired. The upper surface  16   a  may also be curved with relatively wide or relatively narrow undulations, the latter in a corrugated form (not shown). Still further, the upper surface  16   a  may be patterned, textured (as shown in selected ones of  FIGS. 5 and 9  through to  15 ) or otherwise provided with indicia of a predetermined design theme, to present a clean esthetically pleasing outer surface to be complementary with the décor of the vicinity of the structure. 
   Referring to  FIGS. 2   a  to  2   g , another support device  30  has a neck  32  provided with a transverse passage  34  extending therethrough for engaging an installation tool  36 . As with the above mentioned torque tool, the installation tool  36  may be arranged to be hand held. 
   As seen in  FIGS. 2   d ,  2   e ,  2   f , and  2   g , the support device  30  may also be conveniently used with a support accessory  38  which also functions as the installation tool  36 . The support accessory  38  is engageable with a support head portion  40  and is arranged to support an article at a location proximal or distal to the support head portion  40 . In this case, the support accessory  38  includes an anchor formation having a looped portion  42  for engaging the neck  32  and a hooked support formation  44  spaced from the anchor formation  42  and including a support surface  44   a . The support accessory  38 , in this example, can be described as a support hook. 
   Referring to  FIGS. 3   a  and  3   b , the support device  10  has a flat support head portion without a transverse passage through the neck, which is otherwise apparent in the support device  30  of  FIGS. 4   a ,  4   b  and  5 .  FIGS. 6 ,  7  and  8  show the varying styles of support head portions  40  that have an aesthetic appeal and more specifically in  FIGS. 7 and 8  functionality, by having an eight sided support head portion  40  complementary to an eight sided hand tool (not shown). 
   Conveniently, the support device  30  may be packaged together with the support accessory  38  for providing a convenient package for anchoring the support device  30  into a target site of a structure. The support device  30  and the support accessory  38  is adapted for insertion into the target site of the structure  12 , which may include wood, plastic, and paper, cardboard, concrete, brick, steel or a combination of those materials, along with instructions for use. The support device  30  is also desirably made of a material with sufficient strength to support the weight bearing load of at least one kilogram in weight, though other weights may also be suitable, as desired. A most preferred form of material for the support device  30  is metal, such as alloys of aluminum, copper, steel, magnesium and zinc. 
   Referring to  FIGS. 1   a  to  1   c , the support device  10  is secured on wall  12 , by first tapping support head portion so that the elongate shank portion  24  penetrates the wall  12 . The elongate shank portion  24  is next screwed into the target site using a conventional tool such as a screwdriver or even a non-conventional tool such as a butter knife or a nail file. The elongate shank portion  24  is screwed until the shoulder flange  20  abuts the outer surface of the wall  12 , with the support head portion  16  projecting outwardly therefrom. One or more articles may then be mounted on the support head in a number of different orientations, with or without other hanging accessories. A plate (not shown) can be secured in a “plate hanger” of the type which commonly provides an anchoring loop which can be aligned with and placed on the upper region of the neck. A picture frame may be provided with a wire and/or one or more other hanger attachments. 
   Referring to  FIGS. 2   a  to  2   g , the support accessory  38  may be used to deliver the torque for drawing the elongate shank portion  46  into the wall. In this case, the hooked support formation  44  may be oriented to fit within the transverse passage  34  and then manipulated by hand to twist the support device  30  into the wall. 
   Referring to  FIGS. 19   a  through to  19   d , the pre-determined design theme is on a removable cap  48  positioned over the support head portion  16 . The cap has a top portion  48   a  with a beveled edge  50  extending down onto the cap side portion  48   b  which extends around the periphery of the cap  48 . The support head portion  16  has a corresponding beveled edge  50   a  extending around its periphery. When depressed the cap  48  is firmly set on to the support head portion  16 , the cap  48  has an indicia of a pre-determined design theme in the form of, an insignia thereon. 
   Alternatively, the support accessory  38  may be used by aligning the looped portion  42  with the support head portion  40  and orienting the support accessory  38  so that the hooked support formation  40  is placed in an upright ready position. 
   The present invention comprehends various other modifications. For instance, a hook may be hung on the shoulder of the supporting device  30  to accommodate objects. Moreover, the head of the button-head may be configured to accept a given conventional screw-driver. 
   Although the support device  30  of  FIG. 2   a  is useful with a torque tool, for its installation, a wire (for example of the type to mount an article such as a picture) may also be passed through the hole and provided with a force delivery tool to rotate the device thereby driving it into the support structure. 
   Advantageous embodiments of the present invention, provide varying dimensions of the support head portion as well as the neck, flange and elongated shank. For example, the aforementioned dimensions may be increased or decreased depending on the desired holding capacity of the supporting device. The neck and/or shoulder flange may be adapted to accommodate various fasteners which are mounted on an article to be hung from a support structure such as a wall. Examples include saw-tooth hangers, ring fasteners, picture cords, plate hangers, mirror clips and keyhole fasteners. 
   Another advantageous embodiment of the present invention is provided in the material for the support device, which as an alternative to metal, such as alloys of aluminum, copper, steel and magnesium and zinc, there are materials including hardened plastic, Teflon® and Nylon® and other suitable materials. 
   Further advantageous, embodiments of this invention provide a support device that can be easily installed, for example, without requiring conventional tools. The self-tapping feature of the present invention removes a cumbersome installation process known in the art and in replace incorporates the end user with an ease of installation. For instance, the support device may be installed by simply tapping gently on the support device until it penetrates the wall and then by turning the support device with a flat screwdriver, butter knife, nail file or the like. 
   Even further, embodiments of the present invention provide, variable dimensions of the height of the thread, which is measured from a point on the edge to an adjacent point on the surface of the shank, that in effect diminishes progressively from an end of the thread adjacent to the head-support to an end of the thread adjacent to the tip of the shank. 
   Furthermore, embodiments of the invention provide a support device that can support heavy weights, e.g., up to 30 lbs in drywall. Moreover, embodiments of the present invention provide a supporting device when operative having minimal play when installed due to the provision of the flange. More specifically, the flange of load bearing support device is flush against the wall (support structure) that restricts the amount of lateral and/or longitudinal movement of the support device. The variations in the sizes of the flange may be used to accommodate heavier load bearing weights. 
   A further embodiment of the present invention provides a head of the support head portion that receives the torque tool as opposed to any other portion of the support head portion. 
   Even further embodiments of the present invention provide the support device with an indicia of a pre-determined design theme is in the form of an insignia insert. The insert being made of a material or in a combination with another material, for example, paper on metal substrates which are attached to the support head portion as shown in dashed lines at  30   a  in  FIG. 19   a.    
   In an even further embodiment, the present invention provides, for various metal insignias being formed on to the support device during the molding process. 
   Referring to  FIGS. 20 and 21 , a mold is provided at  50  for use in the manufacture of one or more than one support device as described. The mold has a pair of mating surfaces  52 ,  54 , each with a corresponding cavity arrangement  52   a ,  54   a  for producing a blank  56 . In this case, the blank includes a pair of blank portions  56   a ,  56   b  separated by a web  56   c . Lines of weakness are formed at  56   d ,  56   e  which, when severed, yield two support portions  10  as described. 
   Although embodiments of the invention have been described and illustrated in detail, it is to be clearly understood that the same is by way of illustration and example only and not to be taken by way of limitation, the spirit and scope of the present invention being limited only by the appended claims.