FIELD OF THE INVENTION The present invention relates to floating shelves, and more particularly to a system and method for installing a floating shelf with high accuracy.

BACKGROUND OF THE INVENTION Traditionally, shelves are mounted to a wall by supporting them on brackets that remain visible after the shelf is mounted thereon. More recently, the concept of floating shelves has become increasingly popular. In floating shelves the brackets supporting the shelf arc hidden from view by the shelf, thereby making it appear as if the shelf is floating. However, the installation of floating shelves requires high accuracy when drilling corresponding holes in the wall and in the shelf for placing the brackets therein, thus making the installation a difficult and time consuming task, in particular, when the wall is out of plumb and/or weaving. Improper placement of the brackets frequently results in one or more of: the shelf leaning to one side; the shelf sagging forward; the shelf loosening from the wall; and the shelf not being able to bear weight.

While templates and drilling jigs for facilitating the installation of floating shelves are available they are typically limited to a specific length of the shelves and lack in accuracy, in particular, in case the wall is out of plumb or weaving.

A further problem is encountered when a floating shelf is to be mounted to a stud wall such that the shelf is capable of supporting a substantial weight. Mounting of the brackets to the studs makes the installation of the shelf dependent on stud spacing, substantially limiting the choice of shelf length and/or location.

It is desirable to provide a system and method for installing a floating shelf that enables mounting of the floating shelf with high accuracy. It is also desirable to provide a system and method for installing a floating shelf that enables drilling of corresponding bores in the wall and in the shelf with high accuracy when the wall is out of plumb and/or weaving.

It is also desirable to provide a system and method for installing a floating shelf that enables mounting of the floating shelf such that the same is capable of supporting a substantial weight.

It is also desirable to provide a system and method for installing a floating shelf that enables mounting of the floating shelf such that the same is capable of supporting a substantial weight when mounted to a stud wall at a location between studs.

SUMMARY OF THE INVENTION

Accordingly, one object of the present invention is to provide a system and method for installing a floating shelf that enables mounting of the floating shelf with high accuracy.

Another object of the present invention is to provide a system and method for installing a floating shelf that enables drilling of corresponding bores in the wall and in the shelf with high accuracy when the wall is out of plumb and/or weaving.

Another object of the present invention is to provide a system and method for installing a floating shelf that enables mounting of the floating shelf such that the same is capable of supporting a substantial weight.

Another object of the present invention is to provide a system and method for installing a floating shelf that enables mounting of the floating shelf such that the same is capable of supporting a substantial weight when mounted to a stud wall at a location between studs.

According to one aspect of the present invention, there is provided an installation system for installing a wall hanging fixture comprising a wall drilling jig. The wall drilling jig comprises a guide rail vertically which is movable mounted to a first suction cup and a second suction cup in proximity to a first end and a second end thereof, respectively. The suction cups enable removable mounting of the guide rail to a wall. A vertical adjustment mechanism is interposed between the guide rail and each of the suction cups. The vertical adjustment mechanism enables vertically adjusting the guide rail after being mounted to the wall. A drilling attachment is adapted for being mounted at a predetermined location along the guide rail. The drilling attachment comprises a wall drill bit bore oriented substantially perpendicular to the guide rail for guiding a wall drill bit.

According to the aspect of the present invention, there is provided an installation system for installing a wall hanging fixture comprising a wall drilling jig. The wall drilling jig comprises a guide rail vertically which is movable mounted to a first suction cup and a second suction cup in proximity to a first end and a second end thereof, respectively. The suction cups enable removable mounting of the guide rail to a wall. A vertical adjustment mechanism is interposed between the guide rail and each of the suction cups. The vertical adjustment mechanism enables vertically adjusting the guide rail after being mounted to the wall. Furthermore, the guide rail is mounted to the suction cups such that the same is pivotally movable about an axis parallel to a length of the guide rail. A drilling attachment is adapted for being mounted at a predetermined location along the guide rail. The drilling attachment comprises a wall drill bit bore oriented substantially perpendicular to the guide rail for guiding a wall drill bit.

According to the aspect of the present invention, there is provided an installation system for installing a wall hanging fixture comprising a wall drilling jig. The wall drilling jig comprises a guide rail vertically which is movable mounted to a first suction cup and a second suction cup in proximity to a first end and a second end thereof, respectively. The suction cups enable removable mounting of the guide rail to a wall. A vertical adjustment mechanism is interposed between the guide rail and each of the suction cups. The vertical adjustment mechanism enables vertically adjusting the guide rail after being mounted to the wall. A drilling attachment is adapted for being mounted at a predetermined location along the guide rail. The drilling attachment comprises a wall drill bit bore oriented substantially perpendicular to the guide rail for guiding a wall drill bit. The guide rail comprises a drilling attachment groove disposed therein such that the same is oriented substantially parallel to the guide rail. The drilling attachment groove is adapted for enabling mounting of the drilling attachment thereto such that the drilling attachment is movable along the drilling attachment groove. According to the aspect of the present invention, there is provided an installation system for installing a wall hanging fixture comprising a wall drilling jig. The wall drilling jig comprises a guide rail vertically which is movable mounted to a first suction cup and a second suction cup in proximity to a first end and a second end thereof, respectively. The suction cups enable removable mounting of the guide rail to a wall. A vertical adjustment mechanism is interposed between the guide rail and each of the suction cups. The vertical adjustment mechanism enables vertically adjusting the guide rail after being mounted to the wall. A drilling attachment is adapted for being mounted at a predetermined location along the guide rail. The drilling attachment comprises a wall drill bit bore oriented substantially perpendicular to the guide rail for guiding a wall drill bit. The system further comprises a marking transfer strip. The guide rail comprises a marking transfer groove disposed in a top surface thereof such that the same is oriented substantially parallel to the guide rail. The marking transfer groove is adapted for accommodating the marking transfer strip therein.

According to the aspect of the present invention, there is provided an installation system for installing a wall hanging fixture comprising a wall drilling jig. The wall drilling jig comprises a guide rail vertically which is movable mounted to a first suction cup and a second suction cup in proximity to a first end and a second end thereof, respectively. The suction cups enable removable mounting of the guide rail to a wall. A vertical adjustment mechanism is interposed between the guide rail and each of the suction cups. The vertical adjustment mechanism enables vertically adjusting the guide rail after being mounted to the wall. A drilling attachment is adapted for being mounted at a predetermined location along the guide rail. The drilling attachment comprises a wall drill bit bore oriented substantially perpendicular to the guide rail for guiding a wall drill bit. The system further comprises a fixture drilling jig. The fixture drilling jig comprises a base plate adapted for being placed onto a wall facing surface of the fixture and a mounting mechanism for removably mounting the base plate to the fixture. A drilling block is mounted to the base plate. The drilling block comprises a fixture drill bit bore oriented substantially perpendicular to the base plate for guiding a fixture drill bit. The fixture drilling jig further comprises an abutting plate adapted for being placed onto a surface of the fixture oriented perpendicular to the wall facing surface. According to another aspect of the present invention, there is provided a method for installing a wall hanging fixture. A wall drilling jig is provided wherein the guide rail comprises a marking transfer groove disposed in a top surface thereof such that the same is oriented substantially parallel to the guide rail. A marking transfer strip is disposed in the marking transfer groove. Using the suction cups, the wall drilling jig is mounted to a wall at a predetermined location. Using the vertical adjustment mechanism, the guide rail is vertically adjusted such that the wall drill bit bore is at a predetermined height and the guide rail is level. The drilling attachment is moved to a first predetermined location along the guide rail. The first predetermined location is marked on the marking transfer strip. The wall drill bit is inserted into the wall drill bit bore and a first hole is drilled into the wall at the first location. The drilling attachment is then moved to a second predetermined location and the second predetermined location is marked on the marking transfer strip. The wall drill bit is inserted into the wall drill bit bore and a second hole is drilled into the wall at the second location. Using the marking transfer strip, a third and a fourth predetermined location are marked onto the fixture with a distance between the third and the fourth predetermined location being the same as a distance between the first and the second predetermined location. A fixture drilling jig is mounted to the fixture such that the fixture drill bit bore is placed at the third predetermined location. A fixture drill bit is inserted into the fixture drill bit bore and a third hole is drilled into the fixture at the third location. The fixture drilling jig is then mounted to the fixture such that the fixture drill bit bore is placed at the fourth predetermined location. The fixture drill bit is then inserted into the fixture drill bit bore and a fourth hole is drilled into the fixture at the fourth location. After the fourth hole is drilled the fixture drilling jig is removed from the fixture. A first and a second anchor bolt is inserted into the first and second hole, respectively, and secured to the wall. The fixture is the installed by inserting the first and the second anchor bolt into the third and fourth hole, respectively, until the fixture touches the wall.

The advantage of the present invention is that it provides a system and method for installing a floating shelf that enables mounting of the floating shelf with high accuracy.

A further advantage of the present invention is that it provides a system and method for installing a floating shelf that enables drilling of corresponding bores in the wall and in the shelf with high accuracy when the wall is out of plumb and/or weaving. A further advantage of the present invention is that it provides a system and method for installing a floating shelf that enables mounting of the floating shelf such that the same is capable of supporting a substantial weight.

A further advantage of the present invention is that it provides a system and method for installing a floating shelf that enables mounting of the floating shelf such that the same is capable of supporting a substantial weight when mounted to a stud wall at a location between studs.

BRIEF DESCRIPTION OF THE DRAWINGS

A preferred embodiment of the present invention is described below with reference to the accompanying drawings, in which:

Figures 1 to 3 are simplified block diagrams illustrating in a front view and cross sectional side views, respectively, a wall drilling jig of an installation system for installing a wall hanging fixture according to a preferred embodiment of the invention;

Figures 4a and 4b are simplified block diagrams illustrating in a cross sectional side view and a cross sectional top view, respectively, an adjustment mechanism of the wall drilling jig of the installation system for installing a wall hanging fixture according to the preferred embodiment of the invention;

Figures 5a and 5b are simplified block diagrams illustrating in cross sectional side views a wall drill bit bore of the wall drilling jig of the installation system for installing a wall hanging fixture according to the preferred embodiment of the invention;

Figure 6 is a simplified block diagram illustrating in a front view a drilling attachment of the wall drilling jig of the installation system for installing a wall hanging fixture according to the preferred embodiment of the invention; Figure 7 is a simplified block diagram illustrating in a cross sectional side view a toggle bolt for use with the installation system for installing a wall hanging fixture according to the preferred embodiment of the invention;

Figures 8 and 9 are simplified block diagrams illustrating transfer of markings from the wall drilling jig of the installation system for installing a wall hanging fixture according to the preferred embodiment of the invention; and.

Figures 10 to 14 are simplified block diagrams illustrating in a perspective rear view, a perspective front view, a cross sectional side view, a top view, and a top rear view, respectively, a fixture drilling jig of the installation system for installing a wall hanging fixture according to the preferred embodiment of the invention.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the invention belongs. Although any methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, the preferred methods and materials are now described.

While the description of the preferred embodiments hereinbelow is with reference to a floating shelf, it will become evident to those skilled in the art that the embodiments of the invention are not limited thereto, but are also adaptable for installing other wall hanging fixtures such as, for example, wall hanging cupboards and wall hanging cabinets.

Referring to Figures 1 to 14 an installation system 100 for installing a wall hanging fixture according to a preferred embodiment of the invention is provided. The installation system 100 comprises wall drilling jig 101, illustrated in Figures 1 to 6, marking transfer strip 122, illustrated in Figures 2, 8 and 9, and fixture drilling jig 160, illustrated in Figures 10 to 14. The wall drilling jig 101 comprises guide rail 102 which is vertically movable mounted to first suction cup 104A and second suction cup 104B in proximity to a first end and a second end thereof, respectively. The suction cups 104A and 104B are, for example, commercially available 8 inch manually operated pump vacuum suction cups, capable of removably mounting the guide rail 101 to a wall 20. Adjustment mechanisms 124A, 124B are interposed between the guide rail 102 and the respective suction cup 104A, 104B. The adjustment mechanisms 124A and 124B enable vertically adjusting the guide rail 102 after being mounted to the wall 20, as indicated by the up-down block arrows in Figures 1, 2 and 3. Preferably, adjustment mechanisms 124A, 124B are adapted such that the guide rail 102 is additionally pivotally movable about an axis 130 parallel to a length of the guide rail 102, as indicated by angled block arrows in Figures 2, 3, and 4a. Providing vertical as well as pivotal adjustment of the guide rail 102 enables drilling of a plurality of holes at a same level with high accuracy when the wall 20 is out of plumb and/or weaving.

Drilling attachment 114 is adapted for being mounted at a predetermined location along the guide rail 102. The drilling attachment comprises wall drill bit bore 116 oriented substantially perpendicular to the guide rail 102 for guiding a wall drill bit accommodated therein when drilling a hole into the wall 20.

For example, the guide rail 102 with the drilling attachment 114 is mounted to the wall 20 via the suction cups 104A and 104B by manually activating respective pump mechanisms 105A and 105B such that the wall drill bit bore 116 is in proximity to a location of a first hole to be drilled into the wall 20 and such that the longitudinal orientation of the guide rail 102, indicated by bubble level 112, is approximately level with horizontal orientation 10A. The adjustment mechanisms 124 A and 124B arc then used to accurately adjusting the guide rail 102 such that the wall drill bit bore 1 16 is accurately at the location of the first hole and such that the guide rail 102 is accurately level with the horizontal 10A, as illustrated in Figure 1. Preferably, using the adjustment mechanisms 124A and 124B, the guide rail 102 is pivotally moved about the axis 130 until a longitudinal orientation of the wall drill bit bore 116 is accurately level with respect to horizontal orientation 10B, as indicated by bubble level 1 15 of the drilling attachment 114 and illustrated in Figure 2. Further preferably, after the guide rail 102 is accurately adjusted, the same is secured in this position by abutting stabilizers 120 at the wall 20, as illustrated in Figures 1 and 3. For example, six stabilizers 120 are provided with two stabilizers 120 disposed in each end portion of the guide rail 102 and two stabilizers 120 disposed in a center portion of the guide rail 102 with the upper stabilizers being placed below the drilling attachment 114. The stabilizers 120 are, for example, screw bolts accommodated in respective threaded bores 103 disposed in the guide rail 102. The screw bolts are provided with wall engaging feet 121 made of a flexible material such as rubber to prevent damage to the wall 20 when engaging the same.

Further preferably, the guide rail 102 comprises drilling attachment groove 110 disposed therein such that the same is facing away from the wall 20 and is oriented substantially parallel to the guide rail 102, as illustrated in Figures 1 and 2. The drilling attachment groove 110 is adapted for enabling mounting of the drilling attachment 114 thereto such that the same is movable along the drilling attachment groove 110. For example, the drilling attachment groove 110 has a T- shaped cross section for accommodating a respective slider 111 therein. The slider 111 in concert with screw bolt 118 accommodated in respective threaded bore 117 easily enables slidable movement of the drilling attachment 114 along the drilling attachment groove 110, as well as securing same at predetermined locations therealong. For example, after drilling of the first hole into the wall 20, the screw bolt 118 is loosened and the drilling attachment 114 is moved along the drilling attachment groove 110 to a second location. After tightening the screw bolt 118 the drilling attachment 114 is accurately placed for drilling a second hole into the wall 20

The vertical movement, as well as the pivotal movement of the guide rail 102 with respect to each of the suction cups 104 A and 104B is enabled using, for example, swivel block 128 pivotally movable mounted to the respective suction cup 104A, 104B via brackets 126 mounted to the respective suction cup 104A, 104B in a conventional manner using screw fasteners, as illustrated in Figures 4a and 4b. The swivel block 128 is mounted to the brackets 126 using screw bolts 140 accommodated in respective threaded bores 117 easily enables pivotal movement of the guide rail 102 with respect to the suction cups 104A and 104B, as well as securing the same to the suction cups 104A and 104B having a predetermined orientation. The guide rail 102 is, for example, vertically movable mounted to the respective swivel blocks 128 via screw bolts 108A and 108B accommodated in respective threaded bores 132 disposed in the swivel blocks 128. Vertical movement is enabled by providing vertically oriented slots 106A and 106B disposed in the guide rail 102 for accommodating the respective screw bolt 108A, 108B therein. Preferably, the slots 106A and 106B are slightly wider than a diameter of the screw bolts 108A, 108B to allow for some offset in case of a larger difference in the vertical adjustment at the first suction cup 104A and the second suction cup 104B. The guide rail 102 is easily adjusted by simply loosening the screw bolts 108A and 108B, vertically moving the guide rail, and securing the guide rail 102 by tightening the screw bolts 108 A and 108B.

The guide rail 102, the swivel block 128, the brackets 126, and the drilling attachment 114 are made of, for example, aluminum in a conventional manner. Preferably, the wall drill bit bore 116 comprises bushings 146, made of, for example, hardened steel, disposed in respective recesses 142 at the end portions thereof. Each of the bushings 146 is secured using, for example, a split ring 148 disposed in a respective groove 144, as illustrated in Figures 5a and 5b. Alternatively, the bushings 146 are secured using press fit technology.

The guide rail 102 may be provided having various lengths depending on design preferences. Optionally, the guide rail 102 may be adapted for being connected in a conventional manner to an extension guide rail enabling, for example, extension from a length of 48 inches to a length of 96 inches.

Optionally, the drilling attachment 114 comprises, for example, two wall drill bit bores 116A and 116B, as illustrated in Figure 6, to enable drilling of holes having different diameter for mounting different sized anchor bolts for mounting to studs or for drilling of holes for accommodating anchor bolts for mounting to a drywall 20 at locations where there are no studs such as, for example, Snaptoggle® toggle bolts, as illustrated in Figure 7. Commercially available Toggle bolts such as, for example, Snaptoggle® toggle bolts, are commercially available having 250 pound load rating per anchor in 0.5 inch drywall, thus enabling mounting of the fixture such that the same is capable of supporting a substantial weight when mounted to a stud wall at a location between studs. The anchor bolts mounted to studs may be provided as 14 inch to 24 inch lag bolts drilled into 2 x 4 or 2 x 6 studs having 5/8 inch to 3/4 inch diameter with the heads being removed after mounting. Further preferably, the installation system 100 comprises marking transfer strip 122 adapted for being disposed in a respective marking transfer groove 123 disposed in a top surface of the guide rail 102. The marking transfer strip 122 enables transfer of a distance D _w between the location I of the first hole and the location II of the second hole by marking the location of the drilling attachment 114 on the marking transfer strip 122 at the first location MT _l and the second location MT _ll , with the distance D _T between MT _l and MT _ll being the same as D _w , as illustrated in Figure 8. The marking transfer strip 122 is made of, for example, aluminum. During use masking tape may be placed thereupon to enable easy removal of the markings after transfer. Alternatively, the marking transfer strip 122 is made of a material that enables easy dry erasing of the markings such as, for example, melamine. Optionally, the marking transfer strip 122 is secured to the marking transfer groove 123 in a conventional manner using, for example, split pins.

After drilling of the first and the second hole in the wall 20, the marking transfer strip 122 the markings MT _l and MT _ll is removed from the marking transfer groove 123 and placed onto a wall facing surface 40A of the fixture such as shelf 40, as illustrated in Figure 9. For example, after adjusting the marking transfer strip 122 such that each of the markings MT _l and MT _ll is approximately a same distance from an end of the shelf 40, the markings MT _l and MT _ll are transferred onto a surface 40B oriented perpendicular to the wall facing surface 40A using, for example, a right angle ruler. The markings MS _l and MS _ll are then accurately placed with a distance D _s being equal to the distance D _w therebetween.

As is evident to one skilled in the art, the marking transfer strip 122 may also be employed for transferring more than two markings, for example, in case more than two anchor bolts are needed for supporting the fixture.

After transfer of the markings fixture drilling jig 160 is removably mounted to the shelf 40.

The fixture drilling jig 160 comprises base plate 162 which is adapted for being placed onto the wall facing surface 40A of the shelf 40, as illustrated in Figures 10 to 14. Drilling block 166 is mounted to the base plate 162. The drilling block comprises fixture drill bit bore 167 oriented substantially perpendicular to the base plate 162 for guiding fixture drill bit 50. Preferably, the fixture drilling jig 160 comprises abutting plate 164 which is adapted for being placed onto a surface 40B of the fixture oriented perpendicular to the wall facing surface 40A. Further preferably, marking M167 is disposed, for example, onto the abutting plate 164 with the marking M167 indicating the location of the centre axis of the fixture drill bit bore 167 in order to facilitate accurate placement of the fixture drilling jig 160 by simply adjusting the same until the marking M167 coincides with one of the markings MS _l or MS _ll . The fixture drilling jig 160 is removably mounted to the shelf 40 using, for example, screws 168 for temporarily mounting the fixture drilling jig 160 to the wall facing surface 40 A of the shelf 40, and/or clamping mechanism 170 in contact with surface 40C opposite surface 40B. The components of the fixture drilling jig 160 are made of, for example, wood or aluminum, in a conventional manner. Preferably, the fixture drill bit bore 167 comprises bushings, made of, for example, hardened steel, disposed in respective recesses at the end portions thereof as described hereinabove.

Using the installation system 100 a wall hanging fixture is easily installed. The wall drilling jig 101, having the marking transfer strip 122 disposed in the marking transfer groove 123 and the drilling attachment 114 mounted thereto, is mounted to the wall 20 using the suction cups 104A and 104B at a predetermined location such that such that the wall drill bit bore 116 is in proximity to a location of a first hole to be drilled into the wall 20 and such that the longitudinal orientation of the guide rail 102, indicated by bubble level 112, is approximately level with horizontal orientation 10A.

Using the adjustment mechanisms 124A and 124B the guide rail 102 is accurately adjusted such that the wall drill bit bore 116 is at the accurate vertical location of the first hole and such that the guide rail 102 is accurately level with the horizontal 10A. Preferably, using the adjustment mechanisms 124A and 124B, the guide rail 102 is pivotally moved about the axis 130 until a longitudinal orientation of the wall drill bit bore 116 is accurately level with respect to horizontal orientation 10B, as indicated by bubble level 115 of the drilling attachment 114. After the guide rail 102 is accurately adjusted, the same is secured in this position by abutting stabilizers 120 at the wall 20.

The drilling attachment 114 is moved to the location of the first hole along the guide rail 102 and secured thereto. The first location MT _l is marked on the marking transfer strip 122. The wall drill bit is inserted into the wall drill bit bore 116 and the first hole is drilled into the wall 20. The drilling attachment 114 is then moved to the location of the second hole along the guide rail 102 and secured thereto. The second location MT _ll is marked on the marking transfer strip 122. The wall drill bit is inserted into the wall drill bit bore 116 and the second hole is drilled into the wall 20. After completion of the second hole, the wall drilling jig 101 is removed from the wall 20

The marking transfer strip 122 is removed from the marking transfer groove 123 and placed onto the wall facing surface 40A of the shelf 40. The markings MT _l and MT _ll are transferred onto a surface 40B oriented perpendicular to the wall facing surface 40A as markings MS _l and MS _ll . The markings MS, and MS,, accurately indicate a third and a fourth location for drilling respective holes into the shelf 40 having a same distance D _s therebetween as the distance D _w between the first and the second hole in the wall 20.

The fixture drilling jig 160 is mounted to the shelf 40 such that the fixture drill bit bore 167 is placed at the third location. The fixture drill bit 50 is inserted into the fixture drill bit bore 167 and the third hole is drilled into the shelf 40 at the third location.

The fixture drilling jig 160 is then mounted to the shelf 40 such that the fixture drill bit bore 167 is placed at the fourth location. The fixture drill bit 50 is inserted into the fixture drill bit bore 167 and the fourth hole is drilled into the shelf 40 at the fourth location. After completion of the fourth hole the fixture drilling jig 160 is removed from the shelf 40.

A first and a second anchor bolt are inserted into the first and second hole, respectively, and secured to the wall. The shelf is then installed by inserting the first and the second anchor bolt into the third and fourth hole, respectively, until the shelf 40 touches the wall 20.

The present invention has been described herein with regard to preferred embodiments. However, it will be obvious to persons skilled in the art that a number of variations and modifications can be made without departing from the scope of the invention as described herein.