Anchor device for weak substrates

Abstract

An anchoring device to support an object upon weak substrates such as wallboard, plaster walls or paperboard. A frame supports multiple long fasteners such as nails at an angle relative to the substrate. The frame includes angled fastener channels formed in segments by opposed mold core elements. The mold cores create slots that are parallel to a mold pull direction, and further are angled relative to the fastener channels. The slots expose sides of the fastener channels, alternating channel sidewalls being exposed in adjacent segments of each channel. Tabs are provided along a perimeter of the frame to create full slots to hold a wire or other thin part of an object to be supported. A recess creates a gap under each fastener head to enable a thin prying tool to remove the fastener.

1 . A device for anchoring objects to a substrate wherein: 
 a one piece frame includes a top portion and a bottom portion, the bottom portion defining a substantially planar attaching face;    a plurality of elongated fastener channels extend from openings in the top portion to openings in the bottom portion, a longitudinal orientation of the fastener channels being angled with respect to the attaching face, and at least some of the fastener channels further being angled with respect to other of the fastener channels;    elongated slots extending into the frame in a vertical direction substantially perpendicular to the attaching face, the slots angled with respect to the longitudinal orientation of the fastener channels, the slots extending into the fastener channels to create openings in sidewalls of the fastener channels;    the fastener channels being divided into segments of fastener channel length by the slots, adjacent segments of the fastener channels alternately being exposed toward the bottom face and being exposed away from the bottom face, the exposure being through the openings in the sidewalls of the fastener channels created by the slots.    
   
   
       2 . The anchoring device of  claim 1  wherein the fastener channels axially confine elongated fasteners, and a portion of each fastener is exposed by each slot.  
   
   
       3 . The anchoring device of  claim 1  wherein the openings in the top portion are through planar fastener landings of the frame, a plane of each fastener landing facing parallel to the longitudinal orientation of the fastener channels.  
   
   
       4 . The anchoring device of  claim 3  wherein elongated fasteners are axially confined by the fastener channels, the fasteners include enlarged heads with an underside of the heads contacting the landings, a recess extends into each landing to create a gap under part of each head.  
   
   
       5 . The anchoring device of  claim 1  wherein the frame includes an external perimeter, at least one upper tab extends outward from the perimeter to form a downward facing shelf, at least one lower tab extends outward to form an upward facing shelf proximate along the perimeter to the upper tab, the opposed shelves forming a slot that extends along the perimeter of the frame, the upper and lower tabs not overlapping in the vertical direction.  
   
   
       6 . A method to manufacture a device for anchoring objects to a substrate including the steps of: 
 creating a mold cavity by means of two opposed mold halves, the mold halves being separated at a parting line, the mold halves further separating in a single pull direction, a molded material being inserted into the mold cavity to form an attaching device frame;    molding a plurality of elongated fastener channels of the frame that extend from openings in a top portion of the frame to openings in a bottom portion of the frame, a longitudinal orientation of the fastener channels being angled with respect to the pull direction, and at least some of the fastener channels further being angled with respect to other of the fastener channels;    forming elongated slots of the frame by means of mold cores extending into the mold cavity in the pull direction, further creating elongated slots of the frame by means of mold cores extending into the mold cavity opposite to the pull direction, the slots thereby angled with respect to the longitudinal orientation of the fastener channels, the slots extending into the fastener channels to create openings in sidewalls of the fastener channels;    dividing the fastener channels into segments of fastener channel length by the slots, alternately exposing adjacent segments of the fastener channels in the pull direction and opposite to the pull direction, the exposure being through the openings in the sidewalls of the fastener channels created by the slots.    
   
   
       7 . The anchoring device of  claim 6  including the step of installing elongated fasteners into the fastener channels of the frame.  
   
   
       8 . A device for anchoring objects to a substrate wherein: 
 a frame includes a top portion and a bottom portion, the bottom portion defining a substantially planar attaching face;    a plurality of elongated fastener channels extend from openings in the top portion to openings in the bottom portion, a longitudinal orientation of the fastener channels being angled with respect to the attaching face, and at least some of the fastener channels further being angled with respect to other of the fastener channels;    the frame includes an external perimeter, at least one upper tab extends outward from the perimeter to form a downward facing shelf, at least one lower tab extends outward to form an upward facing shelf proximate along the perimeter to the downward facing shelf of the upper tab, the opposed shelves forming a slot that extends along the perimeter of the frame, the upper and lower tabs not overlapping in the vertical direction.    
   
   
       9 . The anchoring device of  claim 8  wherein the opposed shelves are immediately adjacent to each other.  
   
   
       10 . The anchoring device of  claim 8  wherein a plurality of slots are spaced along the perimeter of the frame.  
   
   
       11 . A device for,anchoring objects to a substrate wherein: 
 a frame includes a top portion and a bottom portion, the bottom portion defining a substantially planar attaching face;    a plurality of elongated fastener channels extend from openings in the top portion to openings in the bottom portion, a longitudinal orientation of the fastener channels being angled with respect to the attaching face, and at least some of the fastener channels further being angled with respect to other of the fastener channels;    the openings in the top portion are through planar fastener landings of the frame, a plane of each fastener landing facing parallel to the longitudinal orientation of the fastener channels;    a recess extends into each landing to create lowered portion of the landing.    
   
   
       12 . The anchoring device of  claim 10  wherein elongated fasteners are axially confined by the fastener channels, the fasteners include enlarged heads with an underside of the heads contacting the landings, the lowered portion provides a gap under part of each head.