Patent Publication Number: US-2020281376-A1

Title: Wall Cleat and System for Hanging Items

Description:
CLAIM OF PRIORITY 
     This application claims priority from U.S. Provisional Patent Application No. 62/816,110, filed Mar. 9, 2020, entitled: “Wall Cleat and System for Hanging Items,” the contents of which are incorporated herein, in their entirety. 
    
    
     BACKGROUND 
     a) Field of the Invention 
     The present invention generally relates to hanging hardware and, more particularly to such hardware used to hang framed pictures and other items on a wall surface. 
     b) Description of the Prior Art 
     A variety of different types of hardware and hanging systems have been developed over the years to secure items to a wall. A seemingly simple task, yet each year improvements continue to be found. Typically, for lightweight picture frames, for example, a simple nail or screw in the wall can be used adequately for hanging. In such instance, the head of the nail or screw merely abuts against a portion of the frame, along an inside surface. With this simple arrangement, the nail or screw does not mechanically or reliably engage the picture frame, but simply relies on friction contact to precariously hold the frame in place against the wall surface—the frame effectively balances on the head of the nail or screw. This delicate balance of the frame on the nail or screw fastener is such that it is susceptible to shifting, tilting or possibly even falling from the perch at the slightest bump or perhaps during some event (e.g., an earthquake or the vibrations caused by a truck passing nearby). 
     Another commonly used fastener is the so-called “D-ring”, which is usually secured to the back of a picture frame in pairs, and, as the name implies, is shaped like the letter “D.” D-rings work well to support even heavy frames to a wall surface, but require the framer to secure each D-ring at a correct location to the back of the frame during assembly. For one picture frame, this is a relatively simple task, but if you&#39;re in the business of selling picture frames and assemble perhaps thousands of frames a week, then the time spent to install the D-ring hardware to each frame quickly adds up and affects the unit cost of each picture frame and the overall cost of doing business. The actual cost of the D-ring hardware and the accompanying screws must also be considered when evaluating the use of this type of fastener. Other issues related to the use of D-rings include installation accuracy. If the D-rings are not installed to the frame in close horizontal alignment with respect to each other, the user who mounts the frame to a wall will encounter difficulties in accurately positioning the wall-hardware (screws and anchors, or nails) so that they align with the D-rings and provide a level frame arrangement. 
     Another fastener commonly used for hanging lighter frames is the keyhole bracket, which is a metal plate, and like the above-described D-rings, are secured in pairs to the back of a picture frame. The keyhole bracket includes a keyhole-shaped cutout for receiving and capturing the head of a screw by guiding the shaft of the screw into a narrow channel. Like the above-described D-ring, the keyhole bracket is very effective at holding picture frames to walls. Unfortunately, keyhole brackets must also be accurately horizontally aligned and secured to the frame using screws and, as in the case with the D-rings, this takes time and time is a cost. 
     Yet another type of hanging hardware for picture frames is called a French cleat, which includes a product-mounted elongated cleat and a wall-mounted elongated cleat. The two cleats are usually made from wood and are shaped with a matching angular surface which are sized and shaped to snugly engage each other at the time of hanging. The two cleats are relatively long and can therefore distribute heavy loads across a larger area so that a smaller force will affect each contact point. The engagement allows even very heavy items to be supported on a wall. 
     Although the French cleat system has a proven track record at effectively and safely supporting even the heaviest of frames to walls, the frame installer is still burdened with the task of accurately mounting the product side cleat to the back of the frame. If the installer secures this product side cleat slanted or off-centered, the wall-mounted process will be difficult. Another problem with French cleats is that they often require access to the inside edge of the upper member of the frame. This is typically where the product-side cleat is secured since it is a strong part of the frame, but unfortunately it makes it difficult to include a backing paper to the frame. This may not be a problem with some applications, such as mirrors and some pictures, but many frame applications remain where a backing paper is desired, such as framed canvases and other open frame artwork. 
     OBJECT OF THE INVENTIONS 
     It is a first object of the present invention to provide a hanging system for use with picture frames which overcomes the deficiencies of the prior art. 
     It is a second object of the present invention to provide a hanging system for use with picture frames which is inexpensive to implement and use. 
     SUMMARY OF THE INVENTION 
     A frame mounting system for hanging frames on a wall surface includes a wall-mount cleat and a product-side cleat. The product-side cleat is integrally-formed into at least one side frame rails of a frame during the manufacture of the frame. The two cleats are sized and shaped to selectively snugly engage each other. A user simply mounts the wall-mount cleat level to a wall surface and then positions the frame against the wall so that the product-side cleat engages the wall-mount cleat. An additional feature of the present invention is a flat surface that is formed in the frame member adjacent to the integrally formed cleat. This flat surface is sized and shaped to receive and support a backing material using either staples or an appropriate adhesive to help protect the rear of the picture or painting. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a front perspective cutaway view of a picture mounting system, according to a first embodiment of the invention, showing a picture frame engaged with a wall mount cleat; 
         FIG. 2  is a rear perspective cutaway view of the picture frame and wall mount cleat of  FIG. 1  showing the wall mount cleat engaged with the frame, according to the first embodiment of the invention; 
         FIG. 3  is a rear perspective cutaway view of the picture frame of  FIG. 1 , according to the first embodiment of the invention; 
         FIG. 4  is a perspective view of the wall mount cleat of  FIG. 1 , according to the first embodiment of the invention; 
         FIG. 5  is a side view of the picture mounting system, according to the first embodiment of the invention, showing the picture frame of  FIG. 1  disengaged from the wall mount cleat; 
         FIG. 6  is a side view of the picture mounting system, according to the first embodiment of the invention, showing the picture frame of  FIG. 1  engaged with the wall mount cleat; 
         FIG. 7  is a cutaway perspective view of a picture mounting system, according to a second embodiment of the invention, showing a picture frame engaged with a wall-mount cleat; 
         FIG. 8  is a side view of the picture mounting system, according to the second embodiment of the invention, showing the picture frame of  FIG. 7  disengaged from the wall mount cleat; 
         FIG. 9  is a side view of the picture mounting system, according to the second embodiment of the invention, showing the picture frame of  FIG. 7  engaged with the wall mount cleat; 
         FIG. 10  is a cutaway perspective view of a picture mounting system, according to the second embodiment of the invention, showing a picture frame disengaged with the wall mount cleat; 
         FIG. 11  is a perspective view of the present hanging system showing a picture being hung onto a wall-mounted cleat, according to the present invention; 
         FIG. 12  is a perspective view of the wall-mount cleat, according to the second embodiment of the invention; and 
         FIG. 13  is a perspective view of a hanging system, according to the present invention, showing a shelf item (representing 3-dimensional hanging items) secured to a cleat mounted to a wall surface. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     By way of introduction, the present invention is a new mounting system for securing generally planar items to a wall surface and includes a wall-mounted cleat and a frame-mounted cleat. The system works with many different planar items, such as picture frames, mirrors, pin-boards and many types of decorative items. In addition to planar items, such as picture frames, the present system may also be used to mount more 3-dimensional rectangular prism items, such as shelving (an example of a shelf is shown in  FIG. 13  and described below), wherein a portion of the item extends perpendicular from the wall surface. For the purpose of clarity, all of these suitably mountable items (picture frames, mirrors, shelving, etc.), planar or 3-dimensional in shape, according to the present invention, are collectively referred to as “frames” in describing the present invention. The present mounting system, as described in greater detail below will work with frames made from any of a variety of materials including, but not limited to, wood, ceramic, plaster, metal, glass and plastic. 
     Referring to  FIGS. 1 and 2 , a picture mounting system  10 , according to a first embodiment of the invention is shown including a frame  12  and a wall-mounted cleat  14 . Frame  12  is shown as a representative wall-mountable item, according to the present invention and includes a front surface  16 , a rear surface  18 , an upper member  20  and a side member  22 . In this embodiment, only a portion of a typical rectangular picture frame is shown in these figures so that details of relevant features and structure of the present invention can be clearly shown enlarged. Of course, a conventional square or rectangular picture frame  12  will include upper member  20 , two side frame members  22  and a lower member (not shown) forming a generally rectangular shape. Also, although frame  12  is shown and described herein as a rectangular or square shape, it can take on any of a variety of shapes, and as mentioned above, and may be a shelf, mirror, or any other similar item that is typically mounted to a wall, without departing from the gist of the invention. 
     Referring now to  FIG. 4 , wall-mount cleat  14  is shown as an elongated shaped member and includes a mounting section  24 , an angled engagement section  26  (also called a projection) and a level-receiving channel  28 . Mounting section  24  lays flat against wall surface  15  when wall-mounted cleat  14  is mounted to wall surface  15  and includes at least one hole  32  (preferably one hole  32  is provided at every inch along the length of wall-mount cleat  14 ). Holes  32  located through mounting section  24  are provided at points along the length of cleat  14  and are sized and shaped to receive appropriate hardware  34  for securing cleat  14  to wall surface  15 , as shown in  FIG. 6 . Appropriate hardware  34  includes screws, nails, and bolts. Holes  32  are preferably formed along their own respective central hole axis (not shown). Each hole axis is, in this first embodiment aligned generally perpendicular to flat mounting section  24  and also wall surface  15 , as shown in  FIG. 6 , so that fasteners penetrate perpendicularly into wall surface, as understood by those skilled in the art. 
     As shown in  FIGS. 1, 2, 5 and 6 , angled engagement section  26  extends upward, towards a ceiling and outward, away from the wall surface at a prescribed angle, when wall-mount cleat  14  is mounted to wall surface. Engagement section  26  of cleat  14  defines a rear engagement surface  27  (which faces wall surface  15 ), a front angular surface  30  (facing away from wall surface  15 ), and has a prescribed thickness. According to a preferred embodiment of this invention, cleat  14  is made from aluminum, using, for example, a conventional and well known extrusion process. The cleat extrusion is typically made in long lengths (e.g., about 20 feet) and later cross cut to form a shorter cleat (to any desired length, such as 6, 8 or 12 inches). The length of the cleat will vary depending on the size and weight of the frame. A preferred wall cleat  14  is currently available by Hangman Products, Inc. of Simi Valley, Calif. 93065, and at www.hangmanproducts.com. 
     Level-receiving channel  28  of wall-mount cleat  14  is sized and shaped in cross-section to slidingly receive a cylindrical bubble-level vial (shown in  FIGS. 7-9 and 12 ) so that wall mount cleat  14  effectively functions as a carpenter&#39;s level. This allows the user to quickly and easily level wall mount cleat  14  against wall surface  15  without having to use an additional leveling tool. Channel  28  includes an arcuate sectional shape (“C” shape) which circumferentially extends sufficiently to effectively secure an appropriately sized cylindrical bubble-level vial when one is inserted into channel  28 . As mentioned above, wall-mount cleat  14  is preferably made from aluminum, but may be made from a variety of other materials, including other types of metal, wood and plastic and may or may not include channel  28 . In such instance, an extrusion process of manufacture may not be appropriate and other processes may be required, depending on the material. For example, a wood shaper or router may be appropriate to make a wooden cleat, while an injection molding process (or extrusion) may be appropriate for a cleat made from plastic. At the very least, for wall-mount cleat  14  to perform according to this first embodiment of the invention, it must include the above-described angular engagement section  26 , flat mounting section  24 , and appropriate fasteners to secure the cleat to wall surface  15 . The provision of channel  28  is preferred, but optional for the present invention to work properly. 
     According to the preferred embodiment of the present invention, frame-side cleat is formed integrally with the formation of frame  12 . Using a conventional picture frame construction as an example to illustrate the present invention, and referring to  FIGS. 1-6 , upper member  20  of frame  12  has a shaped section which includes an inwardly slanted cleat-channel  36  that defines an angular engagement surface  38 . According to the invention, cleat-channel  36  is formed into rear surface  18  of frame  12  so that angular engagement surface  38  faces the inside of the frame (away from wall surface  15 ). It is preferably formed along the entire length of upper member  20 , but can also be formed along just a portion of one or more frame members. Additionally, since picture frame members (if made from wood), are shaped following a predetermined sectional shape along the entire length of stock wood using an aptly-named power tool called a shaper, slanted cleat-channel  36  can easily be cut along the entire length of all the frame members that are used to make up frame  12 . A shaper or router can also be used to shape frame members made from plastic as well. Metal (such as aluminum) frame members may be shaped using an appropriate extrusion die to include cleat-channel  36  and angular engagement surface  38 , and other features according to the invention, as described in greater detail below. 
     Referring to  FIGS. 1-6 , frame  12  further includes a picture-holding channel  40  for receiving a pane of glass or plastic, artwork and a matte, etc., depending on the type of frame. Also provided in the frame structure is a flat surface  42  that is sized and shaped to receive and support a backing material  44  by staples, an appropriate adhesive, or some other securing means appreciated by those skilled in the art. Flat surface  42  is an important feature of the present invention because it allows a protective backing material  44 , such as paper, fabric, plastic or metal sheet or wood panel, to continue to fully protect the rear surface of the artwork while still providing wall mount cleat  14  access to inside cleat-channel  36  and angular engagement surface  38 . Flat surface  42  can also be used to support various mechanical fasteners that are commonly used to engage and hold pictures, glass, mirror sheet, picture mattes, and backing boards (called planar materials) within frame  12 . These are usually metal tabs and are typically bent over the planar materials to hold them in place within frame  12 , as understood by those of ordinary skill in the art. 
     As mentioned above, using wood frame rails to explain the present invention, angular engagement cleat-channel  36  is preferably formed during the shaping of the frame rails  20 ,  22  using a router, a shaper, or other conventional and well known wood-cutting tools. Engagement surface  38  of cleat-channel  36  is preferably a prescribed acute angle less than 50 arc degrees (as measured from the vertical, such as the wall surface). The exact angle of engagement surface  38  may vary, but preferably matches the angle of rear angular surface  26  of cleat  14  so that when the two cleats engage each other, as shown in  FIG. 6 , rear angular engagement surface  26  of cleat  14  contacts a majority of angular engagement surface  38  of frame  12 . This close mechanical engagement between the two cleats helps hold the frame securely to the wall-mount cleat and wall  15 , as shown in  FIG. 6 . 
     The shape and size of angular engagement cleat-channel  36  is such that when frame  12  engages with wall-mount cleat  14  (by following the direction of the arrow shown in  FIG. 5 ), rear surface  18  of frame  12  preferably firmly contacts wall surface  15 , as shown in  FIG. 6 . The contacting surfaces of rear surface  18  of frame  12  and wall surface  15  causes a slight binding effect that is essentially the result of the tapered geometry of the angular surfaces of cleat  14  and the cleat-channel  36 . This mechanical interaction keeps the frame firmly in place against the wall and the two cleats engaged (the angular engagement surfaces push the frame firmly into the wall). If the frame did not firmly contact wall surface  15 , frame  12  would end up being loosely supported by the two cleats and could easily disengage if moved or bumped. When wall mount cleat  14  engages with cleat-channel  36 , there is sufficient clearance between rear surface  18  of frame  12  and protective backing material  44  to accommodate fasteners  34  (see  FIGS. 5 and 6 ) and level holding channel  28 . 
     Since cleat-channel  36  is formed automatically during the shaping of each frame before the assembly of frame  12 , then the product side cleat (which is defined by cleat-channel  36 ) will be present at all sides of frame  12  (since the same frame stock would be used to make the frame). In such instance, the user may quickly and easily reorient a frame between landscape and portrait orientations, as desired, simply by repositioning the frame and re-engaging the wall mount cleat  14  with cleat-channel  36  of an adjacent frame member. Also, since the product side cleat (which functions essentially as a fastener) is simply cut into each frame rail while the frame rails are being cut and shaped, there are no extra steps in the manufacturing process. Additional hardware is not required and no additional time is wasted securing hardware to the rear of the product, as in conventional frame securing systems, described in the background section of this application. By forming cleat-channel  36  into frame rails early in the production of frame  12 , the accuracy of each cleat-channel  36  is preset by the cutting machines themselves and is therefore much better controlled than trying to accurately position and secure hanging hardware to the rear surface of each frame after the frame is already assembled. Also, formation of cleat-channel  36  will not affect the finish of frame  12 . Securing hardware in conventional frames would occur after a finishing process and the installation thereof could damage the finish. 
     The exact shape of cleat-channel  36  of frame  12  and the shape of engagement section  26  of cleat  14  may be one of many different shapes without departing from the gist of the present invention. Whatever shapes are used, cleat-channel  36  and wall cleat  14  should be able to firmly engage each other, when desired. 
     According to a second embodiment of the invention, as shown in  FIGS. 7-12 , a frame-mounting system  100 , including a frame  102  and a cleat  104 . As in the above described first embodiment of the invention, cleat  104  is secured to a wall surface  106  using appropriate fasteners  108  (in this embodiment, as described below, fasteners  108  are preferably nails or brads). Frame  102  includes a longitudinal angled channel  110  which is sized and shaped to snugly receive an angled engagement section  112  of cleat  104  during mounting. The main differences between the second embodiment and the first embodiment is that cleat  104  includes a mounting section  105  that is angled with respect to wall surface  106  so that fasteners  108  may be guided into wall surface  106  at a prescribed angle. In contrast, mounting section  26  of cleat  14  in the above-described first embodiment is flat (parallel to wall surface  15 ), since the fasteners used in that embodiment are designed to penetrate wall surface  15  perpendicularly. Also, angled cleat-channel  36  provided in the above described first embodiment is an angled channel  110  in this second embodiment which allows frame  102  to more securely engage with cleat  104  during mounting. 
     Referring to  FIG. 12 , mounting section  105  of cleat  104  includes several bores  114 , spaced evenly along the length of the cleat (preferably one bore every inch). Bores  114  are angled with respect to wall surface  106 , (between 30 and 50 degrees, as measured from the vertical) so that fasteners  108  will penetrate wall surface  106  at an effective holding angle to enable a maximum load in shear (so that cleat  104  will be able to support the heaviest load possible, within prescribe safety limits). Additional bores  114  and fasteners  108  may be provided to allow cleat  104  to support greater loads in shear against wall surface  106 . Fasteners  108  are preferably thin brads that minimize damage to wall-surface  106  and do not require any pre-drilling. This allows cleat  102  to be used effectively in apartments wherein a renter is discouraged from damaging any wall surface. 
     As shown in  FIG. 12 , cleat  104  is preferably made from extruded aluminum, plastic, or similar and, as in the first embodiment, preferably includes a level-receiving channel  116  to selectively and slidingly receive a level vial  118  to allow a user to quickly and easily level cleat  102  against a wall during mounting. 
     As shown in  FIGS. 7-10 , frame  102  includes frame members  120 , which includes angled channel  110 , preferably cut into frame members using an appropriate tool, such as a table saw (not shown) with the blade set at a desired angle. According to this second embodiment of the present invention, similar to the above-described first embodiment, frame members  120  here also include a cutout  122  to support a planar picture and glass  124 , and an adjacent surface  126  to support a protective rear panel  128 . 
     According to the invention, angled channel  110  is sized to slidingly receive angled engagement section  112  and is cut to match the angle of section  112  so that frame  102  may be selectively secured to cleat  104  by engaging angled engagement section  112  with channel  110 . 
     As shown in  FIG. 12 , it is preferred that cleat  104  includes a longitudinally displaced channel  107  located along a rear surface (adjacent wall surface  106 ) which is sized and shaped to receive bores  114 . Channel  107  is angled to help guide fasteners  108  from each respective bore  114  into wall surface  106  so that the predetermined penetration angle is maintained. This channel  107  also allows for uniform wall thickness throughout the extrusion, as is appreciated by those skilled in the art of extrusion processes. Finally, channel  107  allows for bores to be relatively shallow in depth. This is beneficial because, as such, bores may be formed (such as by using a drilling process) more quickly and easily since there would be less material to cut. 
     In use of this invention, a user securely mounts cleat  104  against wall surface  106  of a wall in a desired location. The user may insert bubble vial  118  into channel  116  so that cleat  104  may be mounted level. While holding cleat  104  level against wall surface  106 , appropriate fasteners  108  (such as brads) are used by inserting one into each bore  114  and using an appropriate tool (such as a brad-hammer) to force each fastener through bore  114  and channel  107  and into wall surface  106 , still maintaining the prescribed angle which is determined by bores  114 . 
     Once all appropriate fasteners  108  are used and cleat  104  is secured to wall surface  106 , bubble vial  118  is removed from channel  116  and picture frame  102  is positioned so that upper member  120  is positioned above cleat  104  and so that angled channel  110  aligns with an upper edge of angled engagement section  112  of cleat  104 . Once aligned, the user moves frame downward and towards wall surface  116  so that angled engagement section  112  enters into channel  110 . Frame  102  may be lightly tapped down so that a rear contact surface of frame  102  firmly contacts with wall surface  106 , creating a friction engagement. Frame  102  is now firmly secured to the wall. 
     Referring now to  FIG. 13 , a shelf  200 , according to a third embodiment of the invention is shown, including a representational “L” shape structure. Shelf  200  is used to illustrate that 3-dimensional items may be secured to wall surface  202  using a wall cleat  204  in a similar manner that frame  102  is secured to the wall in the above described second embodiments, using cleat  104 . The shape and dimensions of shelf  200  shown in  FIG. 13  may vary without departing from the present invention. According to this embodiment, an upper section  206  of shelf  200  includes an angular engagement channel  208  (which is essentially identical to channel  110  of the above-described second embodiment, referring to  FIG. 8 ). Owing to the downward forces generated by a load positioned on shelf  200 , the shelf further preferably includes a wall-contact boss  210  which is sized, shaped and positioned to abut against wall surface  202  just below cleat  204 , as appreciated by those skilled in the art. Cleat  204  functions identical to cleat  104  of the above-described second embodiment and may be secured to the wall using either the angled fasteners method described in the second embodiment, or the perpendicular fastener method described in the first embodiment. As in the second embodiment, shelf  200  is secured to cleat in an identical manner wherein a user positions a rear side of the shelf against wall surface  202  so that an engagement section  212  enters into angular engagement channel  208 . Shelf  200  is then forced firmly into wall surface  202  as it moves downward onto angled engagement section  212  of cleat  204 . 
     Accordingly, an invention has been disclosed in terms of preferred embodiments thereof which fulfill each and every one of the objects of the present invention as set forth above and provides a new and improved picture hanging system and method. Various changes, modifications and alterations from the teachings of the present invention may be contemplated by those skilled in the art without departing from the intended spirit and scope thereof.