Patent Publication Number: US-2017350147-A1

Title: Magnetic Fasteners And Wall Cover System

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. Application Ser. No. 62/344,115 filed on 1 Jun. 2016, the contents of which are incorporated herein by reference. 
    
    
     TECHNICAL FIELD 
     The present invention relates generally to wall fasteners, wall plates and wall covers, and more particularly to a magnetic fasteners and wall cover system. 
     BACKGROUND 
     The statements in this section merely provide background information related to the present disclosure and may not constitute prior art. 
     At some point and time, virtually every residential and/or commercial building will encounter an issue that requires a user to repair drywall. In many instances, the need will arise from unintentional damage caused to a wall or other surface. In many other instances, users need to remove a portion of the sheetrock in order to access one or more components located within the walls of the building. Whether it is an electrical junction box, a pluming line or an HVAC component, the fact remains that the drywall must be removed before the same can be accessed. 
     Although the process of cutting and removing the drywall is relatively simple and does not require specialized tools or knowledge, the same is not true for repairing the wall upon completion of the task. As such, the sheetrock repair industry has been unable to provide a reliable wall repair system and method that are simple, fast, and strong. Traditional wall repair systems, for example, include a myriad of supplies and equipment that must be used to repair even small wall holes. Specifically, a typical drywall repair kit includes a curable, setting-type repair compound (or “mud”), drywall tape, sandpaper, a compound spreader, a cutting tool, a mixing tray, a mixing stick, sheetrock replacement panels, and more. Nearly all of these tools and supplies are required to complete even a relatively minor drywall repair job. 
     Moreover, the traditional wall repair methods that use these systems are difficult and time-consuming. This is because the traditional approach to repairing holes in sheetrock walls requires a series of fairly complex steps. Specifically, the traditional approach for repairing drywall damage begins by mixing the repair compound. Next, the user must prepare a hole cover out of a sheet of replacement sheetrock that is cut to a size that exactly matches the hole and/or must cut a porous wall patch or strips of drywall tape must be placed over the hole. The curable repair compound is then applied to the damaged wall area over the new drywall piece, the porous wall patch and/or drywall tape. Once the repair compound is applied, it must be allowed to cure. 
     Unfortunately, even fast-curing repair compounds take approximately between 60-90 minutes to cure. Other repair compounds may take a day or more to cure. After the compound cures, the repaired area must be sanded flush with the rest of the wall. Following sanding, a texture coat must be applied to the repaired area to match the texture of the surrounding wall area. Finally, once the texture coat has dried, the repaired area is painted to match the color of the surrounding wall area. 
     Although more recent efforts have seen the introduction of pre-mixed patches which can be adhered over the drywall hole, such items have met with limited commercial success because the lightweight structure of such patches often results in the same becoming indented or damaged with the lightest of contact. Moreover, such systems do not allow a user to repeatedly access the drywall opening, as may be the case in instances where periodic maintenance and/or recurring problems occur. As such, the user must repeat the laborious steps described above each time the need to access the opening are required. 
     The present invention, directed to a magnetic fastener and wall covering system differs from the conventional art in a number of aspects. The manner by which will become more apparent in the description which follows, particularly when read in conjunction with the accompanying drawings. 
     SUMMARY OF THE INVENTION 
     The present invention is directed to a magnetic fastener and wall covering system. One embodiment of the present invention can include at least one wall panel having a front facing surface, a metallic rear facing surface and a side surface forming any number of different shapes such as oval, round, square or rectangle. The wall cover can include any number of decorative elements such as a picture, or texturing, so as to allow the cover to blend with a surrounding wall. 
     The present invention can also include a plurality of wall fasteners and wall anchors that can function alone or together to engage a wall. A plurality of magnetic washers can be provided. Each of the washers can include a central aperture for receiving one of the plurality of wall fasteners, and can function to mate with the metallic rear surface of the wall panel when the same is installed onto a wall. 
     The present invention can also include one or more wall strips having a magnetic top surface and an adhesive back surface. The magnetic surface of each of the wall strips can function to mate with the metallic rear surface of the wall panel when the same is installed onto a wall. 
     This summary is provided merely to introduce certain concepts and not to identify key or essential features of the claimed subject matter. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Presently preferred embodiments are shown in the drawings. It should be appreciated, however, that the invention is not limited to the precise arrangements and instrumentalities shown. 
         FIG. 1  is an exploded parts view of the magnetic fastener and wall covering system that is useful for understanding the inventive concepts disclosed herein. 
         FIG. 2A  is a front side view of a wall panel of the magnetic fastener and wall covering system, in accordance with one embodiment of the invention. 
         FIG. 2B  is a back side view of a wall panel of the magnetic fastener and wall covering system, in accordance with one embodiment of the invention. 
         FIG. 3  is a side view of the fastener and magnetic washer of the magnetic fastener and wall covering system, in accordance with one embodiment of the invention. 
         FIG. 4  is a perspective view of the magnetic washer of the magnetic fastener and wall covering system, in accordance with one embodiment of the invention. 
         FIG. 5  is a perspective view of the wall strip of the magnetic fastener and wall covering system, in accordance with one embodiment of the invention. 
         FIG. 6A  is a perspective view of the magnetic fastener and wall covering system in operation, in accordance with one embodiment of the invention. 
         FIG. 6B  is a cross sectional view of the magnetic fastener and wall covering system in operation, in accordance with one embodiment of the invention. 
         FIG. 7A  is another perspective view of the magnetic fastener and wall covering system in operation, in accordance with one embodiment of the invention. 
         FIG. 7B  is another cross sectional view of the magnetic fastener and wall covering system in operation, in accordance with one embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     While the specification concludes with claims defining the features of the invention that are regarded as novel, it is believed that the invention will be better understood from a consideration of the description in conjunction with the drawings. As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention which can be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the inventive arrangements in virtually any appropriately detailed structure. Further, the terms and phrases used herein are not intended to be limiting but rather to provide an understandable description of the invention. 
     Although described throughout this document for use with a building wall, the inventive concepts are not limiting to any particular application or material. As such, the system can be utilized equally on any type of surface such as a wall, floor, ceiling or cabinet in any type of structure such as a building, mobile home, or vehicle, for example. 
       FIGS. 1-7B  illustrate various embodiments of a magnetic fastener and wall covering system  10  that are useful for understanding the inventive concepts disclosed herein. In each of the drawings, identical reference numerals are used for like elements of the invention or elements of like function. For the sake of clarity, only those reference numerals are shown in the individual figures which are necessary for the description of the respective figure. For purposes of this description, the terms “upper,” “bottom,” “right,” “left,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the invention as oriented in  FIG. 1 . 
       FIG. 1  is an exploded parts view of the system components in accordance with one embodiment. As shown, the system  10  can include, essentially, one or more panels  20 , having any number of wall fasteners  30 , magnetic washers  40  and/or magnetic attachment strips  50 . 
     As shown in  FIGS. 2A and 2B , each of the wall panels  20  can include a main body having a front facing surface  21 , a metallic rear facing surface  22 , and a plurality of side surfaces  23 . In various embodiments, raised edges  24  can be provided along the outside periphery of the rear facing surface  22  and can provide a separation distance  26  between the rear facing surface  22  and the wall  1  onto which the panel is to be installed (see  FIGS. 6B and 7B ). 
     As described herein, the panel can include any number of different sizes and shapes, such as square, rectangular or circle, for example, and can be constructed from any number of different materials such as plastic, metal, wood and/or composites, for example. In various embodiments, the panel can include a two-material construction, wherein the front facing surface  21  is constructed from plastic having a color and texture that matches traditional drywall, and the rear facing surface  22  is constructed from a sheet of thin metal. In such an instance, these materials can be permanently secured together in accordance with any known manufacturing process such as welding, casting or through the use of adhesives, for example. 
     In addition to the above, the panel  20  can also include any number of decorative elements  25  such as various colors, markings, words, shapes, symbols, logos, designs, lights, types of materials, texturing of materials, patterns, images, and/or photographs, for example. Such decorative elements can be secured onto and/or into the main body in accordance with known techniques so as to be flush with the surface of the main body or can be raised/protruding outward from the main body so as to give a three dimensional effect. 
     In this regard, the decorative elements can be provided to make the panel stand out from the surrounding wall by providing a picture, for example, or can be provided to make the panel blend in with the surrounding wall by providing a textured surface that matches drywall texture. In such an embodiment, the front facing surface will preferably include a material that is suitable for receiving and retaining paint, so as to allow a user to paint the panel to match the color of the wall. 
     The plurality of wall fasteners  30  can include or comprise any number of different elements that are capable of being secured onto or within building materials such as drywall/sheetrock, block and/or wood, for example. As shown in  FIG. 3 , the fasteners  30  can include any number of elongated screws  31  having a main body  31   a,  a screw head  31   b  and a plurality of screw threads  31   c  along the length of the screw body. The fasteners  30  can also include any number of generally hollow and expandable wall anchors  35  having an opening  35   a  for receiving the screw  31  and a body  35   b  which can expand behind the surface of a building wall. Several nonlimiting examples of wall anchors can include, for example, expanding plastic anchors, lag screw shields, expanding, toggle wing, wedge and/or drywall self-drilling anchors, for example. Of course, in various embodiments, the screw threads  31 c of the screws  31  can be constructed to grip a particular building material such as wood studs, for example, in order to be secured directly onto a wall without the use of an anchor  35 . 
     Each of the magnetized washers  40  can include a generally circular shaped body  41  having a central aperture  42  a top surface  43  and a bottom surface  44 . The washer can be constructed from any type of metal and can be magnetized in accordance with known processes. The washer can include any number of different sizes (e.g., diameter of the main body) and/or thicknesses (e.g., distance from the top surface  43  to the bottom surface  44 ). In either instance, the central aperture  42  can include a dimension that is suitable for receiving the main body  31   a  and screw threads  31   c,  but that is less than the dimension of the screw head  31   b  of the same screw  31 . 
     As shown in  FIG. 4 , one embodiment of the washer  40  can include a raised outer periphery  43   a  that is greater than the depth/height of the screw head  31   b,  so as to allow the screw head of any screw positioned within the aperture  42  to be located flush with, or entirely beneath the outer periphery  43   a.  As will be shown and described below, such a feature ensures that no matter how many wall fasteners are being utilized, each one will have a smooth magnetic outer surface providing an identical separation distance  26  (see  FIGS. 6B and 7B ) between the wall  5  and the metallic rear facing surface  22  of the wall plate  20 . Moreover, by providing washers of various thicknesses, a user can select the separation distance, wherein selecting a plurality of thicker washers provides a greater separation distance than a plurality of thinner washers. 
     As shown in  FIG. 5 , the system can also include a plurality of wall strips  50  each having a magnetized top surface  51  and a back surface  52  that is covered with an adhesive  52   a  such as glue or resin, for example. The strip can be provided with a removable covering layer  53  until ready for use. Each of the strips can be provided in any length, width and/or thickness, and can allow the system to be utilized on walls and other surfaces such as tiles, for example, where it is preferable to utilize a peel-and-stick type of fastener in addition to, or in lieu of the above described fasteners  30 . 
       FIGS. 6A and 6B  illustrate one embodiment of the system  10  in operation to cover an opening  5  in a wall  1 . As shown, one or more of the wall fasteners  30  having a magnetic washer  40  can be screwed into the drywall  1  at locations adjacent to the opening  5 . If a stud  2  is present, the screw  31  can be secured directly to the stud, otherwise a wall anchor  35  can be used. Next, the user can select a panel  20  having a shape and size that is suitable for covering the opening  5 . Upon selecting the panel, the user can simply place the metallic rear facing surface  21  next to the magnetic washers  40 , and the magnets will pull the panel against the wall and secure the same thereon. 
     Likewise,  FIGS. 7A and 7B  illustrate one of the system  10  in operation to cover a damaged portion  500  of a tile wall  100 . As shown, one or more of the magnetic strips can be adhered to the tile wall  100  by removing the protective layer and pressing the same onto the wall. Next, the user can select a panel  20  having a shape and size that is suitable for covering the damaged tile members  500 . In the present example, the selected panel includes markings  25  in the form of a picture that matches the design of the tile wall  100 , so as to allow the panel to blend in with the wall. Upon selecting the panel, the user can simply place the metallic rear facing surface  21  next to the magnetized top surface  51 , and the magnetized surfaces will pull the panel against the wall and secure the same thereon. 
     As such, the system  10  can be utilized to quickly and easily position any number of wall panels along a wall or other type of structure for any number of different reasons. Moreover, as the fasteners  30  and  50  can each engage the entire rear facing surface of the panel, the system advantageously does not require a user to precisely measure distances on or about the wall, or to ensure that the fasteners are level with each other. Such a feature represents a substantial improvement to the conventional systems and allows users a simple and cost effective means for covering walls without requiring specialized tools or knowledge. 
     As described herein, one or more elements of the system  10  can be secured together utilizing any number of known attachment means such as, for example, glue, compression fittings and welds, among others. Moreover, although the above embodiments have been described as including separate individual elements, the inventive concepts disclosed herein are not so limiting. To this end, one of skill in the art will recognize that one or more individual elements such as the screw  31  and the washer  40 , for example, may be formed together as one continuous element, either through manufacturing processes, such as welding, casting, or molding, or through the use of a singular piece of material milled or machined with the aforementioned components forming identifiable sections thereof. 
     As to a further description of the manner and use of the present invention, the same should be apparent from the above description. Accordingly, no further discussion relating to the manner of usage and operation will be provided. 
     The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. 
     The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present invention has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the invention. The embodiment was chosen and described in order to best explain the principles of the invention and the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated.