Abstract:
An improved mounting system for use with display units and other devices of various sizes. A mounting system of the present invention includes a surface mounting bracket and at least one device mounting bracket. At least one of the surface mounting bracket and the at least one device mounting bracket is expandable such that it is able to accommodate and support devices of different dimensions and weights.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     The present application claims priority to U.S. Provisional Patent Application No. 60/836,866, filed Aug. 10, 2006 and incorporated herein by reference in its entirety 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to mounting systems. More particularly, the present invention relates to mounting systems for devices such as flat panel televisions. 
     BACKGROUND OF THE INVENTION 
     This section is intended to provide a background or context to the invention that is recited in the claims. The description herein may include concepts that could be pursued, but are not necessarily ones that have been previously conceived or pursued. Therefore, unless otherwise indicated herein, what is described in this section is not prior art to the description and claims in this application and is not admitted to be prior art by inclusion in this section. 
     In recent years, flat panel televisions have become enormously popular in both commercial and residential sectors. As the prices for plasma and liquid crystal display (LCD) flat panel displays have continued to fall, and the quality for the same devices have improved, more and more businesses and individuals have purchased such devices for both home and business entertainment purposes. 
     One of the advantages of flat panel television units that customers have found particular appealing is their relatively low thickness. Because conventional “tube” televisions have a relatively large depth, the display options for such devices are quite limited. In the residential setting, most users require a television stand or large entertainment center to store the television. Such stands or entertainment centers can take up significant floor space, which is often undesirable. In the commercial or educational setting, users will often install large overhead mounting systems that can contain the television. However these systems usually require professional installation. With flat panel televisions, on the other hand, users are presented with a relatively new option: mounting the television directly to the wall. By mounting the television to the wall, a person can eliminate the need to take up potentially valuable floor space. 
     Although the introduction of flat panel televisions on a wide scale has presented new opportunities to both residential and commercial customers, it has also presented new challenges. In particular, flat panel televisions, while usually having significantly smaller depth or profile than conventional “tube” televisions, tend to be quite heavy. Particularly for flat panel televisions with large screens, this weight can become also prohibitively great. With such large weights involved, it is especially important that users can easily, safely, and securely mount the devices without having to make substantial adjustments. 
     A number of conventional wall mounting systems involve the use of a relatively large wall surface mounting bracket and a plurality of device mounting brackets that are configured to attach to the back of a television or other display device. Each device mounting bracket typically includes a screw or similar fastener that is used to secure the device mounting bracket relative to the wall surface mounting bracket. One such conventional device mounting bracket includes a pair of side portions which bound a mounting contact portion. An upper hook and a lower guiding portion are located on each side portion, which together define a receiving region for the wall surface mounting bracket. The upper hook is formed on each of the side portions at substantially the same position. A plurality of openings are used to connect the conventional device mounting bracket to a television or other flat panel display. 
     Although useful, mounting systems of the type described above include certain shortcomings. In particular, current mounting systems include device mounting brackets and wall surface mounting brackets that are sized specifically for television ranges of certain sizes. As would be understood by those skilled in the art, it is important that these components not be too small to adequately support the load of the display unit. If these components are too small, there is a substantial risk that the mounting system will not be able to support the entire load, which could lead to substantial damage to the display unit and potential physical injury to people in the vicinity of the display unit. Furthermore, it is also important that the individual mounting system components not be too large for a particular display unit, as this could result in the mounting system extending beyond the edges of the unit, which is aesthetically unpleasing. 
     In light of the above issues, manufacturers of television mounts have had little choice but to make multiple models of the same mounting systems, with each model being designed specifically for a particularly range of television sizes. Although this arrangement serves the need of both the manufacturer and the consumer, the necessity to manufacture multiple models of the same product adds to the complexity and cost on the part of the manufacturer, and these costs ultimately are passed onto the consumer. The existence of multiple models also increases the complexity for the installer of the mounting system, as he or she must make sure that the proper mount has been acquired for installation. 
     It would therefore be desirable to develop a mounting system that addresses the above shortcomings while still providing the user with a structurally sound and safe product. 
     SUMMARY OF THE INVENTION 
     The present invention provides for an improved mounting system for use with display units and other devices of various sizes. A mounting system of the present invention includes a surface mounting bracket and at least one device mounting bracket. At least one of the surface mounting bracket and the at least one device mounting bracket is expandable such that it is able to accommodate and support devices of larger dimensions and weights. In one embodiment of the invention, device mounting bracket extension members can be connected to the top and/or bottom of the device mounting brackets, resulting in the device mounting brackets being lengthened and permitting the device mounting bracket to reach farther towards the top and bottom edges of larger devices. In another embodiment, the wall plate is expandable in the left-to-right direction, permitting the wall plate to reach farther towards the right and left edges of larger devices. With these extension mechanisms, a single mounting system can be used for mounting devices of many different sizes. 
     These and other advantages and features of the invention, together with the organization and manner of operation thereof, will become apparent from the following detailed description when taken in conjunction with the accompanying drawings, wherein like elements have like numerals throughout the several drawings described below. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a mounting system constructed according to one embodiment of the present invention; 
         FIG. 2  is a perspective view showing the interaction between a device mounting bracket and a device mounting bracket extension mechanism in the mounting system of  FIG. 1 ; 
         FIG. 3  is a reverse perspective view showing the interaction between a device mounting bracket and a device mounting bracket extension mechanism in the mounting system of  FIG. 1 ; 
         FIG. 4  is a reverse perspective view showing the device mounting bracket and the device mounting bracket extension mechanism separated from each other; 
         FIG. 5  is a side view of an extension bracket flange intended for use on a lower portion of a device mounting bracket  24 ; 
         FIG. 6  is a reverse perspective view of a device mounting bracket extension mechanism constructed in accordance with an alternate embodiment of the present invention; 
         FIG. 7  is a left side view of a device mounting bracket and a device mounting bracket extension mechanism according to an alternate embodiment of the present invention; 
         FIG. 8  is a front view of the arrangement shown in  FIG. 7 ; 
         FIG. 9  is a perspective view of the arrangement shown in  FIG. 7 ; 
         FIG. 10  is a perspective view of a portion of a surface mounting bracket extension mechanism in accordance with  FIG. 1 ; 
         FIG. 11  is a front view of a surface mounting bracket extension mechanism in accordance with one alternative embodiment; 
         FIG. 12  is a front view of a surface mounting bracket extension mechanism in accordance with another alternative embodiment; 
         FIG. 13  is a front view of a surface mounting bracket extension mechanism in accordance with yet another alternative embodiment; 
         FIG. 14  is a front view of a surface mounting bracket extension mechanism in accordance with still another alternative embodiment; and 
         FIG. 15  is a front view of a surface mounting bracket extension mechanism in accordance with another alternative embodiment. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       FIG. 1  shows a mounting system  20  constructed in accordance with one embodiment of the present invention. The mounting system  20  includes a surface mounting bracket  22  and a plurality of device mounting brackets  24 . In the embodiment of the invention shown in  FIG. 1 , two device mounting brackets  24  are used. However, virtually any number of device mounting brackets  24  may be used depending upon factors such as the size and weight of the item to be mounted. The surface mounting bracket  22  is configured to be mounted to a wall or other flat surface via a variety of surface mounting plate openings  26  and fasteners (not shown), while the device mounting brackets  24  are configured to attach to the back of a display unit such as a flat panel television. In the embodiment depicted in  FIG. 1 , the device mounting brackets  24  include an upper hook portion  30  for accepting an upper portion of the surface mounting bracket  22 . 
     As shown in  FIG. 1 , each device mounting bracket  24  includes a device contact bracket  32  and a mounting contact bracket  35 . In various embodiments, the device contact brackets  32  each comprise a device contact bracket base  29  with device contact bracket flanges  33  extending therefrom. A plurality of followers (not shown) are used to couple the device contact bracket  32  and the mounting contact bracket  35  through a plurality of guide structures  37 . As a result of this arrangement, the device contact bracket  32  is movable relative to the surface mounting bracket  22 . In one embodiment of the invention, the guide structures  37  comprise substantially straight slots. However, other arrangements are also possible. In another embodiment depicted in  FIGS. 7-9 , a movable friction crank  39  may be used to selectively adjust the frictional resistance of the device mounting bracket  24  relative to the surface mounting bracket  22  and to lock the position of these components relative to each other. 
     The device contact bracket  32  includes an elongated upper portion  27  and an elongated lower portion  28  along a longitudinal axis thereof. The device contact bracket  32  also includes a plurality of device bracket contact slots  31  and/or holes along a longitudinal axis thereof. The device bracket contact slots  31  and/or holes are used to couple the device mounting bracket  24  with the back side of a television, display unit, or other audio/visual device via mounting holes contained thereon. 
     As shown in  FIGS. 1-4 , one or more bracket extension mechanisms  38  are removably connected to the various device mounting brackets  24  as necessary. Each bracket extension mechanism  38  includes a base portion  40  and a pair of extension bracket flanges  42 . The base portion  40  includes a plurality of base portion slots  47  therein. The base portion slots  47  are sized and arranged to also align with mounting holes on the back side of the device to be mounted. 
     As shown in  FIGS. 1-4 , each extension bracket flange  36  includes a series of extension bracket slots  44  formed therein, with each extension bracket slot  44  aligning with a corresponding extension bracket slot  44  on the opposite bracket extension flange  36 . The extension bracket slots  44  are configured to align with at least one projection  43  located on the elongated upper portion  27  and/or elongated lower portion  28  of the device mounting bracket  24 . In various embodiments of the present invention, the projections  43  can comprise, for example, pins, screws, bolts, etc. (and combinations thereof) that are positioned within respective elongated upper and lower portions  29  and  28 . In the case of screws, bolts or similar fasteners, a tightening of these components can be used to securely fasten the extension bracket flange  36  to the elongated upper portion  27  and/or elongated lower portion  28 . As shown in  FIG. 4 , for example, each projection  43  can attach to one device mounting bracket flange  46  of the device mounting bracket  24 , in which case additional projections  43  can be used for an opposite device mounting bracket flange  46  if necessary. However, it is also possible for a single projection  43  to attach or otherwise operably connect to both device mounting bracket flange  46  of a device mounting bracket  24 . 
     As shown in  FIGS. 1-4 , the extension bracket slots  44  are angled upwards moving from an edge of the extension bracket flange  36  towards the center thereof. In this arrangement, when the projections  43  mate with desired extension bracket slots  44 , the extension bracket flange  36  “holds” the device mounting bracket  24  in place.  FIG. 5  shows a similar arrangement for an example extension bracket flange  36  intended for use on the bottom of the device mounting bracket  24 . 
     The bracket extension mechanisms  38  are used to extend the effective surface length of the device mounting bracket  24  as necessary. In a case where a relatively small and/or lightweight display device is to be mounted, the normal length of the device mounting bracket  24  may be sufficient to enable the device mounting bracket  24  to fully support the device. On the other hand, if a much larger and/or heavier device is to be mounted, a user can locate bracket extension mechanisms  38  on the elongated upper and lower portions  29  and  28  as necessary, creating a longer elongated surface for operably connecting to the back of the device. Additionally, the user is provided with the ability to modify the amount of additional length that is provided by selecting the appropriate extension bracket slots  44  for mating with the projections  43 . 
       FIG. 6  shows another embodiment of the invention. In  FIG. 6 , the plurality of extension bracket slots  44  are replaced by extension holes  41  on the bracket extension mechanism  38 . The extension holes  41  are sized to accept pins, screws, other types of projections that can also attach to the device mounting bracket  24 . It is also possible to use both extension bracket slots  44  and extension holes  41  on the same extension bracket flanges  36  if necessary or desired. In each of these embodiments, it is also possible to include length markers  50 , which can aid a user in identifying and selecting the appropriate extension bracket slots  44  to use during the mounting process, as well as ensuring that the same extension bracket slots  44  are used for each bracket extension mechanism  38  in a mounting system  20 . 
     In various embodiments of the invention, the surface mounting bracket  22  is expandable in addition to or instead of the device mounting bracket  24 . FIGS.  1  and  10 - 15  show various versions of such an expandable surface mounting bracket  22 . As depicted in these figures, the surface mounting bracket  22  is formed of multiple components which engage and align each other via one of several mechanisms. 
       FIGS. 1 and 10  depict one expandable surface mounting bracket  22  in detail. The expandable surface mounting bracket  22  in this embodiment comprises modules in the form of a central connection portion  60  and a pair of peripheral portions  62  on each side thereof. The central connection portion  60  is configured to slidably engage each of the peripheral portions  62 . In the embodiment shown in  FIGS. 1 and 10 , this is accomplished by having the central connection portion  60  include upper and lower central connection horizontal support members  64  which are partially offset from corresponding peripheral horizontal support members  66  located on each of the peripheral portions  62 . As a result, the peripheral portions  62  are capable of being slid in front of (or behind in an alternate embodiment) the central connection portion  60  so that the total longitudinal length of the surface mounting bracket  22  can be adjusted as necessary. Once a desired configuration for the surface mounting bracket  22  has been achieved, surface mounting bracket fasteners  68  such as short screws are used to secure the peripheral portions  62  to the central connection portion  60 . 
       FIGS. 11-15  show various particular embodiments of expandable surface mounting bracket  22 . It should be understood, however, that a wide variety of arrangements can be used for the expandable surface mounting bracket  22 .  FIG. 11  shows an arrangement where the central connection portion  60  and the peripheral portions  62  include interlocking regions  70 , which permits these components to mate with each other. In this arrangement, different central connection portions  60  and peripheral portions  62  can be mixed and matched in order to create surface mounting brackets  22  of different sizes.  FIG. 12  shows a three-part arrangement that is similar to the arrangement shown in  FIGS. 1 and 10 . However, the central connection portions  60  in  FIG. 12  does not include upper and lower central connection horizontal support members  64 . Instead, the central connection portions  60  can fit within a groove or slot on the back of the peripheral portions  62 , for example, or simply be placed behind the peripheral portions  62  to achieve a desired arrangement. 
       FIG. 13  shows yet another embodiment of the surface mounting bracket  22 . In this embodiment, it is shown that more than three components may be used. In this particular embodiment, a plurality of identical or different modules  72  may be used in succession, allowing a user to create a surface mounting bracket  22  of virtually any length necessary for a mounting process. 
       FIGS. 14 and 15  show yet other embodiments of a surface mounting bracket  22 , where only two modules  72  are used. In  FIG. 14 , the two modules  72  slidably engage with each other and are fastened to each other by the use of a connection bracket  74 , which slidably engages the modules  72 . In  FIG. 15 , no connection bracket may be necessary. 
     The foregoing description of embodiments of the present invention have been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the present invention to the precise form disclosed, and modifications and variations are possible in light of the above teachings or may be acquired from practice of the present invention. The embodiments were chosen and described in order to explain the principles of the present invention and its practical application to enable one skilled in the art to utilize the present invention in various embodiments and with various modifications as are suited to the particular use contemplated.