Hidden Mantel Mounting Assembly for Variable Stud Alignment
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Solution Overview
Problem
Conventional hidden shelving mounting hardware designs face issues with alignment due to varying wall stud spacings, are not suited for thicker or reclaimed wood mantels with imperfections, and require complex manufacturing processes, leading to reduced weight-carrying capacity and aesthetic concerns.
Innovation Solution
A mantel made of solid reclaimed wood with a hidden mounting assembly featuring a sheet metal bracket and deep slot/recess configuration that allows for secure alignment and attachment to wall studs, enabling flexible placement and minimizing manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If predrilled rod receiving holes are spaced at a fixed distance to retain weight supporting integrity, then the weight carrying capacity is improved, but the alignment with varying wall stud spacings deteriorates
Solution Approach 1:
The patent transforms the fixed, static hole spacing into a dynamic adjustment mechanism. The elongated slot in the bracket allows the rod to be positioned at varying distances from the edge, enabling adaptation to different wall stud spacings while maintaining structural integrity. This dynamic positioning resolves the contradiction between fixed spacing for strength and variable spacing for adaptability.
Solution Approach 2:
The invention changes the parameter of hole position from fixed to variable. By replacing a predrilled hole at a specific location with an elongated slot that permits rod placement at multiple positions along the slot length, the system can adjust to different wall stud spacings while maintaining adequate material thickness for load bearing.
2Strength
If larger diameter rods are used to improve weight carrying capacity, then the strength is improved, but the amount of board material removed increases, reducing weight carrying capacity
Solution Approach 1:
The patent replaces a large-diameter rod that would remove significant material with a smaller-diameter rod combined with an elongated slot and adjustment mechanism. The bracket with the slot compensates for the smaller rod diameter by providing a distributed support structure, allowing use of thinner material while maintaining load bearing capacity.
3Ease of manufacture
If conventional hidden shelving mounting hardware is used for thinner shelving boards, then the ease of manufacture is improved, but the adaptability to thicker reclaimed wood mantels deteriorates
Solution Approach 1:
The patent creates a universal mounting bracket design with an elongated slot that can accommodate rods of various diameters and positions, making it suitable for both thin shelving boards and thick reclaimed wood mantels. The same bracket design adapts to different material thicknesses and wood types, achieving universality across applications.
4Strength
If predrilled holes are centrally located between top and bottom surfaces to minimize loss of load bearing capacity, then the strength is improved, but the adaptability to offset alignment with wall studs deteriorates
Solution Approach 1:
The patent replaces the fixed central hole position with a dynamic positioning system using an elongated slot. The rod can be positioned at any location along the slot length, allowing offset alignment with wall studs while the slot geometry and bracket design maintain adequate material distribution to preserve load bearing capacity.
Data Source
AI summary
The invention is a mantel or shelf made of a solid block of reclaimed wood with a hidden mounting assembly. The mantel has sufficient thickness, depth and length to accommodate an elongated L-shaped sheet metal bracket with planar horizontal and vertical flanges to allow selective lateral positioning of the mantel relative to its securement to spaced vertical wall studs. An L-shaped opening in the rear of the mantel is formed by a deep horizontal slot and a shallow vertical recess extending down from the slot. The slot is parallel to and near the top of the mantel, and receives the horizontal flange. The recess receives the vertical flange so the mantel is flush with the wall. A mounting fastener inserted into the mantel pierces the horizontal flange to capture the bracket and secure the mantel to the wall. The bracket, slot and recess are hidden from view during use.