System and Baseplate for Floating Fixtures

The present invention relates to systems for mounting a floating fixture, such as a shelf, to a wall.

Floating fixtures, including shelves or furniture are characterized by not having legs or bottoms that engage a floor, but which are held by a wall. Thus, they appear to “float” above the floor or ground. A challenge in mounting a floating fixture is that they are best mounted to studs of a wall, and the location of studs is often unknown until the installation process begins. Thus, to the extent holes must be drilled in the fixture to facilitate the mounting, it is usually not feasible to do so at a factory where the fixture is manufactured because it is not known how far apart wall studs are located or where along the width of the fixture holes must be drilled. While wide grooves could be formed in the back of a fixture where it abuts a wall, that decreases the structural integrity of the fixture, and requires additional time and labor.

Another challenge is to provide a system that can accommodate tolerances in the location of holes in a fixture that receive support arms that are attached to a baseplate or bracket connected to a wall. For example, suppose two support arms 18 inches apart extend from a wall. It is desirable to drill holes 18 inches apart into the fixture to receive the support arms. However, if the holes drilled into the fixture are slightly off, say, 18 1/14 inches apart, it may not be fixable, and a new and expensive fixture may need to be obtained. Also, even if the holes in the fixture are exactly 18 inches part, when the support arms are adjusted to make the fixture level, the distance between the support arms may need to be adjusted. Thus, it is desirable to provide a floating shelf baseplate or bracket that allows the position of an attached support arm to be horizontally and vertically adjusted, while it is still solidly connected to the wall. Vertical adjustment is important because many walls are not perfectly vertical or plumb, and they may not be perfectly flat.

Another challenge is to provide a system that a homeowner can implement using common household tools and that does not require special skill. Some floating fixture systems require the fixture to have cut grooves cut into it or to have machining made by tools not accessible or familiar to the many homeowners.

Another challenge is to provide a system that allows one person to complete the installation process by him or her self.

Another challenge is to provide a system that allows the position of the fixture to be adjusted while it is mounted or partially mounted to the wall or still connected to the bracket supporting it.

Another challenge is to provide a system that minimizes the number of times the fixture must be lifted and mounted on the bracket. Fixtures are often heavy, so systems that require the fixture to be lifted multiple times during the installation process are not preferred.

Another challenge is to provide a system that retains as much of the physical integrity and strength of the fixture as possible. Some prior systems require that wide grooves or notches be formed in the back of the fixture. This lessens the physical integrity of the fixture and requires time and expense.

Another challenge is to provide a system that allows the fixture to be mounted so it is completely flush against wall or surface to which it is mounted. Some prior systems result in a slight gap between the back of the fixture and the surface or wall, which is less aesthetically pleasing.

Another challenge is to provide a system in which the mounting system structurally supports the fixture not just near the wall or surface, but at a significant distance within the fixture from the wall or surface. The further the fixture supporting mechanism extends into the interior of the fixture, the more weight can be supported by the fixture because there is more load bearing surface area for the supporting mechanism and the weight load is not as concentrated near the point where the fixture abuts the wall or surface.

Another challenge is to provide a system that allows a mounted fixture to be removed and remounted in a different location. With some prior systems, once the mounting hardware and fixture are installed, the holes formed in the fixture to facilitate the mounting make it impossible to remove and remount at a different location.

Some of these challenges are most significant when a floating fixture is expensive or made of rare components. For example, an increasingly popular type of floating fixture is the live edge shelf. These are thick, solid planks of natural wood such as those used for mantles or window seats. The front edge of a live edge shelf is usually the outer surface of the log from which the shelf is cut so the natural or live appearance of the wood is visible. Each live edge shelf is unique, and they are usually expensive. Thus, it is desirable to provide a system that minimizes the risk that the shelf will be damaged during installation while still allowing it to be mounted by a homeowner with modest skills.

A baseplate for holding a support arm is securable to a wall and includes a horizontal T-Channel to receive a channel attachment member, such as a channel nut or channel bolt. A channel nut or bolt can be positioned at a desired horizontal position within the T Channel, and is adapted to engage a support arm to hold a floating fixture. The horizontal position of the channel nut or bolt within the T Channel and an attached support arm may be fixed by rotating the support arm. The baseplate may also have an optional notch having a groove to receive the flange of a threaded bolt to facilitate adjustment of the angle at which a support arm extends from the baseplate. A baseplate and support arm may be combined in a kit for installing a floating fixture such as a live edge shelf. Because the channel support member and support arm are horizontally adjustable with respect to the baseplate, they do not have to precisely match the location of holes in the floating fixture that receive support arms.

shows an exemplary floating fixture, namely a live edge shelf. The back edge will abut a wall after installation.

is a front view of a baseplateadapted to fit into a 1.75″ circular hole in the back of a live edge shelf. The baseplate attaches a fixture such as a live edge shelf to a surface or wall by a first boltand a second bolt. Each of the first and second bolts comprise a threaded end (and), a flangehaving a thread facing surfaceand an opposing surface, and a rotation engagement meansformed in the opposing surface, such as a torx head, star head, flat screwdriver head or Philips screwdriver head. The system may have a channel attachment member, such as a channel nutor channel bolt, that attaches to a support arm(or bracket arm), such as with threads. Also provided is a support arm which has a threaded end having a widthand a bracket engaging surfacehaving width that is wider than the threaded end. Alternatively, if a channel bolt is used in lieu of a channel nut (as discussed below) bracket engaging surfaceshould have a width that is wider than the width of the threads on the channel bolt.

The baseplate may have a wall or structure facing surfaceand an opposing surface, and the wall facing surface having a horizontal slothaving a width. It may also have a first (top) sideand a second (bottom) side. First side may have a first aperturefor receiving the first bolt, the first aperture having a width less than the width of the flangeof the first bolt, such that the first bolt may hold the baseplate to the structure. The second sidecomprising an edgehaving a slot between the structure-facing surface and the opposing surface for receiving the flangeof the second boltsuch the slot does not cover the rotation engagement means of the second bolt while in the slot.

The baseplate may also have a T-slotwithin the baseplate including lipsoperable to slidably receive a channel attachment memberwithin the T-slot, to thereby allow the channel attachment memberand support arm to be horizontally adjusted, and such that the threaded endof the support arm may be rotated so the baseplate engaging surfaceof the support armengages the opposing surfaceof the baseplate, and the channel attachment memberis held against lipsof T-slotto fix the position of channel attachment memberand its attached support armwith respect to baseplate.

Second boltcan be adjustably screwed into the structure while the flange of the second bolt is in the slot of the second side to thereby vertically adjust the angle between the structure and the structure engaging surface of the baseplate. A third sideof baseplate may terminate the end of a T-slot slotoperable to receive a channel attachment memberin the T part of the T slot. In one embodiment, T-Slot extends the width of the baseplate to thereby allow the channel attachment member to be inserted into either end of T slot.

One method to install a floating fixture is as follows. While a live shelf will be shown and discussed as an exemplary embodiment, they system may be used for any kind of fixture. Preferably a support bracket should be installed in each wall stud the fixture will cross, as the wall studs provides the strongest holding power for the fixture. In typical walls, a stud is positioned every 12-18 inches

Baseplates can be attached to the wall at each wall stud (or other secure location) as shown in.

Step-: Using a level or laser level as a guide, draw a horizontal line on the selected wall or area at the desired installation height taking into account the thickness of the shelf top. The line must be as long as the shelf that's being installed.

Step-: Use a stud finder to find wall studs to mount the brackets on within the length of the horizontal line and mark them with them with a vertical line.

Step-: Place an adhesive mounting template on the wall where the shelf bracket will be fastened. The top edge of the template should be on the horizontal line and the vertical center line should match the vertical line on the wall.

Step-: With an impact and a T30 drive bit, drive a 3″ structural screw (or bolt) into the lower indicator on the mounting template leaving approximately ¼″ between the head of the screw and the wall. This hole may be pre-drilled with a ⅛″ drill bit if desired.

Step-: Fit the baseplate on the lower screw and hold it so the top is parallel with the top of the template.

Step-: Fasten the baseplate to the wall by driving the top structural screw (or bolt) through the upper hole of the baseplate. This hole may be pre-drilled with a ⅛″ drill bit if desired.

Step-: Slide the channel nut into the T channel of the baseplate and screw the support arm (bracket rod) into the channel nut. Hand tighten the support arm.

Step-: To level the bracket, place a magnetic level on the top of the support arm and, using an impact with a T30 bit, rotate the bottom screw or boltclockwise or counter-clockwise. Pitch the support arm up slightly to compensate for the weight of the shelf. Make sure to level the support arms with each other. By rotating second bolt, the angle between the structure or wall and the structure engaging surface of baseplate is altered. This allows the fixture, when placed on the support arm(s) to have the desired angle with respect to the wall (usually perpendicular) even if the wall is not perfectly vertical or if the fixture is so heavy that it deflects the support arm.

Repeat steps-to-for each support arm.

Step-: Drill holes in the back of the shelf as described below. Loosen the support arm(s) to align it with the holes in the shelf. This requires horizontally moving the channel attachment member with its attached support arm within the T Slot of the baseplate. Apply silicone caulk into each of the holes in the back of the shelf and slide the shelf onto the support arms until there is about a ½″ gap between the wall/surface and the back of the fixture so the flatsof the support arm(s)remain exposed. Use a wrenchto the flatsand tighten the support arm(s)to the baseplate. Remove the wrenchand push fixturefirmly against the wall, such that the baseplate is covered by the holes formed in the back of the fixture.

As noted above, part of step-is drilling holes in the back of the shelf or other fixture. Steps for this may include the following.

Step-: Measure the distance between the baseplates mounted on the wall, measuring from the center of each baseplate. Mark the back of the shelf accordingly.

Step-: Secure a self-centering drilling jig on the back of the shelf, centering it on one of the marks made in step.

Step-: Drill the shelf:

A. Place an appropriate forstner bit into the appropriate forstner guide. For different shelf thicknesses, forstner bit sizes may be:

Place guide into the self-centering drilling jig. Drill approximately ⅝″ into the back of the shelf.

B. To widen the notch, move the self-centering drilling jig approximately ¼″ to one side and drill approximately ⅝″ into the back of the shelf. Repeat on the other side of the hole.

Place the 9/16″ drill bit guide into the self-centering drilling jig. Using the 9/16″ brad point drill bit, drill a hole for the bracket rod in the center of the first pocket made with the forstner bit. Drill at least 6.5″ deep for the −06 bracket and 8.5″ for the −08 bracket.

Repeat step-for each shelf bracket. Resume Step-as stated above.

While the embodiment discussed above includes a channel nut with female threads and a support arm having male threads, it is also possible to use a channel bolt with male threads and a support arm with female threads.

The baseplate may have a wall or structure-facing surface and an opposing surface, and the wall facing surface may also have a lateral (horizontal) slot having a width. It may also have a first side having a first aperture adjacent the first side for receiving a first bolt, the first aperture having a width less than the width of the flange of the first bolt, such that the first bolt may hold the bracket to the surface by rotating the rotating the first bolt.

is a section view of a channel attachment member that is a channel bolt positioned within a baseplatewhich abuts walland is centered with respect to wall stud. Support armand baseplateare positioned in holes formed in fixture. Support armhas a threaded end with female threadsthat can be screwed onto male threadsof channel bolt. Channel boltis positioned within the T Slot of baseplateand can horizontally slide therein. When support armis fully threaded onto channel bolt, it may cause channel boltmove toward opposing surface of baseplateto engage T slot lips. The tightness of support armand channel bolt against lipfixes the horizontal position of support armwith respect to baseplateand wall.

is a section view of a baseplate abutting wallin which the baseplatehas a horizontal slotinto which the threadsof support arm project, and in which the channel attachment means is a channel nut, and in which the channel nutand support armare not centered in the baseplate. This may be because the location for forming a hole in the fixture was inaccurately measured, which is the type of mistake common for laypersons. It is also possible the location of the hole in fixture has altered due to expansion or contraction of the wall or fixture due to heat, humidity or other factors. This problem can be overcome by sliding the channel attachment member in the T slot. Support armand baseplateare positioned in holes formed in fixture. Support armincludes male threadsthat engage channel nut. Horizontal slotis centered within baseplate, but channel nutis slid to the left of center so that support arm matches the location of the hole formed in fixtureto be mounted. Because the male threadsof support armextend into horizontal slot, the channel nut is captivated with the T slot and cannot slide out unless and until the male support arm is unthreaded from the channel nutuntil it no longer projects into horizontal slot. This arrangement can be advantageous during steps-and-described above in that the channel attachment means and support arm are less likely to accidentally slip out of the T Slot.

is a section view of a baseplate abutting a wallin which the baseplatedoes not have a horizontal slot because the male threadsof the support armare short enough to fit within the T channel of the baseplate. Support armand baseplateare positioned in holes formed in fixture.

The baseplate may be made of aluminum extruded from a die, and cut to a desired width. To facilitate fitting the baseplate in round holes in the back of a fixture or shelf, the corners of the cut extrusion may be cut or milled to be slightly less than the diameter of the round holes, as is evident by comparing the profile shown inwith that shown in.