Abstract:
The present invention provides a system and method of aligning wall or ceiling mounted components. The mounted components are placed within brackets which, in turn, are placed within panels that are embedded into the wall or ceiling. The panels are pre-designed to be installed in precise alignment with respect to one another using various alignment tools or interlocking methods. Once the panels and components are installed into the wall or ceiling, the components are automatically aligned with respect to one another.

Description:
[0001]    This application is a continuation-in-part of Ser. No. 11/954,667 filed Dec. 12, 2007, which is a continuation-in-part of Ser. No. 11/566,365 filed Dec. 4, 2006, which claims priority to provisional application Ser. No. 60/825,162 filed Sep. 11, 2006 and also claims priority to provisional application Ser. No. 60/950,237 filed Jul. 17, 2007 and International application ser. no. PCT/US07/16404 filed Jul. 19, 2007. All prior applications are incorporated by reference in their entirety. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The field of the invention is wall and ceiling receptacles. 
       BACKGROUND 
       [0003]    Plasma screens, speakers, light switches, electrical outlets, recessed lighting, junction boxes and other components are conventionally mounted by cutting a hole in a wall or ceiling, inserting a bracket, and then installing the component into the bracket. When several components are mounted on the same wall or ceiling, installers typically attempt to line up the components or space out the components in an aesthetic pattern. Under those circumstances, being able to mount multiple components in a wall or a ceiling in precise locations relative to one another can become very important to achieve a clean and exacting appearance. However, since the cutouts are performed at the job site, it can be difficult to line up or evenly space multiple components. Even where the task can be performed, there is a considerable amount of work exerted in taking measurements and making minor adjustments. 
         [0004]    One method of lining up mounted components is to attach them along a length of a beam, joist or other substantially straight support structure. U.S. Pat. No. 5,056,287 to Weber teaches a ceiling light system attached directly a ceiling joist along a straight line. U.S. Pat. No. 5,609,007 to Eichner teaches attaching components to a grid in a ceiling. Weber, however, is ineffective at attaching components in positions other than along a ceiling joist, and Eichner cannot be used for recessed components integrated with the existing wall or ceiling. These and all other extrinsic materials identified herein are incorporated by reference in their entirety. Where a definition or use of a term in an incorporated reference is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein applies and the definition of that term in the reference does not apply. 
         [0005]    Lining up components of different sizes along a beam or a grid can also prevent an installer from aligning the components along different axes. In  FIG. 1 , for example, three components of differing sizes  20 ,  30 , and  40  are attached to a side of ceiling joist  10 . Attaching the components directly to the support beam means that the centerlines of the components are out of alignment with one another. U.S. Pat. NO. 6,431,723 to Schubert teaches a method of aligning the centerline of components by adding additional support beams between existing ceiling joists. However, adding additional support beams for each mounted component is time consuming, labor intensive, and is still prone to errors if the installer makes a measurement mistake. 
         [0006]    Another method of mounting components is to prefabricate an entire wall with framed cutouts located where the components are to be installed. US 2007/209,305 to Douglas teaches building pre-fabricated housing with pre-cut windows and pass-throughs. However, building an entire wall in advance at an off-site location is very often impractical, especially when making a late installation decision after a wall has been installed. Additionally, none of the prior art teaches arranging mounted components that achieve a flush-mount appearance in walls, ceilings, and other structures, in which little or even no finishing is required around the periphery of the opening. 
         [0007]    Thus, there is still a need for methods of mounting multiple components in a substantially flat structure of a building at precise locations relative to one another. 
       SUMMARY OF THE INVENTION 
       [0008]    The present invention provides apparatus and methods in which a plurality of components are mounted into a wall, ceiling, or other wallboard by aligning panels with brackets that hold the components. Typically, a wallboard is a building board made for surfacing rather than for insulating ceilings and walls. Wallboards are often made into large rigid sheets that are fastened to the frame of a building to provide a surface finish. As used herein, the term “wallboard” should be construed broadly to mean any sort of mechanical barrier for surfacing ceilings or walls. Wallboards can be made of any suitable material, including for example plywood, plaster, wood, wood pulp, or gypsum. 
         [0009]    Preferred panels have compositions and thicknesses that match the wallboard to which they are being finished, in terms of thickness, composition, and so forth. Where there are differences in composition or thickness, it is preferred that the moisture absorption rate and the thermal expansion rate of the panel and the wallboard differ by no more than 30%, 20%, 10% or 5% from one another to prevent cracking and fraying. Contemplated panel materials include polymers, plasters, woods, fiberboards, and gypsum. The panels can be pre-fabricated away from a construction site, preferably in a factory that can cost-effectively fabricate devices with relatively small tolerances. 
         [0010]    Each panel preferably has at least one receiver that can be factory fabricated into one contiguous assembly. Such receivers can advantageously be made of a strong and durable thermoset bracket, or other material that is more suited to hold a mounted device than the gypsum typically used in wallboards. Providing a pre-fabricated panel designed to accept specific components greatly facilitates installation by eliminating the need for on-site precision measurements. 
         [0011]    Additional receivers can be affixed to openings in the panel, which openings typically extend from a front side of the panel to the back side of the panel. Receivers can range from a simple rim disposed on the inside of the opening to an extensive bracket and housing extending out the back of the panel. In any event, completed assemblies preferably have little or no discernable gap between the panel and the receiver. This can be accomplished in any suitable manner, including for example, accurately cutting the opening into which the receiver is installed and then gluing the receiver to the panel. Where the panel comprises a formed substance such as drywall, another option is to form the panel around the receiver. 
         [0012]    Since the panels are preferably anchored to a support structure using a screw, nail, or similar attachment mechanism, the panels are first aligned with respect to one another before anchoring. Panels can be aligned in any suitable way, for example lining up the edges of the panels, lining up the centerlines of the panels, lining up the centerlines of the receivers, making two edges parallel to one another, or making two edges perpendicular to one another. It is appreciated that aligning the panels in a proper or desirable coordination relative to one another also aligns the receivers relative to one another, and in turn aligns the components relative to one another once everything is installed. 
         [0013]    One or more of the panels preferably have an alignment mechanism to help align panels with one another. In a simple embodiment, the edges of the panels interlock and mate with one another. Such interlocks can advantageously be operated without the use of any tools, for example with snaps, butt joints, dovetails, matching tongues and grooves, matching indents and detents, or matching mortises and tendons. A joint compound, glue, or other such material may be used to permanently or semi-permanently affix the panels to one another, but is not necessary. 
         [0014]    In other embodiments, the edges may be aligned by abutting matching alignment indicators on both panels, and then attaching the panels together using fasteners that couple to fastener receivers on both panels. For example screws could thread into pocket holes, U-bars could be inserted into matching recesses, hooks could be coupled to loops or eyes, nails could be hammered through marked indicators, and pegs can be inserted into matching holes. 
         [0015]    Where the panels do not abut one another, alignment mechanisms more appropriate for distance alignment could be used. For example, an installer could aim a laser light connected to a first panel towards a second panel, and then could adjust the second panel so that the laser light intersects one or more alignment designators on the second panel. Alignment designators could be a line drawn on the panel, or could be two dots that form a line when connected, or could even be an edge of the panel or receiver. 
         [0016]    In preferred embodiments, each receiver has a spackle shield that covers the opening. Receivers can advantageously include useful installation tools, for example a level, installation screws, an alignment mechanism, or installation instructions. In the figures, each of the receivers also has an optional spackle rim or lip that extends outwardly from the front surface of the panel by a small distance. Preferred distances are less than ½ inch (1.27 cm), more preferably by only ⅛ inch (3.175 mm), and even more preferably 1/16 inch (1.5875 mm). Spackling compounds, for example plaster or drywall, can then be smoothed over the surface of the wallboard and panel up to the spackle rims to achieve a contiguous visual appearance. 
         [0017]    Panels are typically installed into the wallboard by first approximating the edges of the panel with the edges of the wallboard to form a junction between the edges. If the junction or gap between the edges is rather large, a buffer can be attached to the edge of the panel before installation, or one or more shims can be installed into the junction. The junction can then be concealed with a concealant, or combination of concealants, to cover the junction from view and establish a superficially continuous junction between the panel and the wallboard. A junction is superficially continuous when the wallboard and the panel appear to be one piece when inspecting the wallboard using visual and/or tactile means. Preferred concealants include tape, plaster, spackling compound, glue, varnish, and paint. 
         [0018]    All types of components are contemplated for installation, but especially including components having electrical parts. For example, speakers, lights, switches, wall plugs, wall controls (audio, video, fan), thermostats, fire sprinklers, fire alarms and smoke alarms, mirrors, kitchen appliances, intercoms, air vents, vacuum outlets, security panels, and iPod docks and ports are all contemplated components. 
         [0019]    The components are preferably locked into place within the receivers using movement restrictors, for example detents, latches, biasing mechanisms, locks, or magnets. Preferably, the movement restrictors engage as the component is inserted into the receiver. “Locking” a component within a receiver means that the component is substantially restricted from moving in a direction relative to the receiver, for example by 2 mm (0.0787 in), 1 mm (0.0394 in), or 0.5 mm (0.197 in). Special removal tools are contemplated for releasing and withdrawing the component. For example a latch can be attached to a ferrous metal or magnet so that a magnetic tool unlocks the latch from the component, allowing it to be removed from the receiver. 
         [0020]    Various objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description of preferred embodiments of the invention, along with the accompanying drawings in which like numerals represent like components. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWING 
         [0021]      FIG. 1  is a plan view of prior art components mounted to a ceiling joist. 
           [0022]      FIG. 2  is a front plan view of a first panel with a laser light and a second panel that is aligned using the laser light. 
           [0023]      FIG. 3  is a front plan view of two panels with interlocking dovetails. 
           [0024]      FIG. 4A  is a front plan view of two panels with an interlocking tongue and groove. 
           [0025]      FIG. 4B  is a horizontal cross-section of along line  4 B- 4 B of the panels of  FIG. 4A   
           [0026]      FIG. 5A  is a rear plan view of a first panel with a recess and a second panel with a recess and a pair of U-bars. 
           [0027]      FIG. 5B  is a horizontal cross-section along line  5 B- 5 B of the panels of  FIG. 5A . 
           [0028]      FIG. 6A  is a rear plan view of a first panel with an angled screw hole and a second panel with a pocket hole. 
           [0029]      FIG. 6B  is a horizontal cross-section along line  6 B- 6 B of the panels of  FIG. 6A  and a screw that fits in the pocket hole and the screw hole. 
           [0030]      FIG. 7A  is a front plan view of a first panel with a pair of recesses, a second panel with a recess and a protruding tab, and a peg. 
           [0031]      FIG. 7B  is a horizontal cross-section along line  7 B- 7 B of the panels of  FIG. 7A . 
           [0032]      FIG. 8  is a front perspective view of one of the brackets in  FIG. 2 . 
           [0033]      FIG. 9  is a simplified vertical cross-section of the panel and bracket of  FIG. 2 , taken along line  9 - 9 , installed in a wall and with an attached speaker. 
           [0034]      FIG. 10  is a blown up view of the circled portion of  FIG. 9 . 
           [0035]      FIG. 11A  is a front perspective view of the bracket of  FIG. 8  positioned to couple with a bracket backing. 
           [0036]      FIG. 11B  is a simplified vertical cross-section of the panel of  FIG. 2 , taken along line  9 - 9 , with the bracket and bracket backing of  FIG. 11A . 
           [0037]      FIG. 12A  is a front perspective view of a panel being affixed to two studs in a wall, the panel having a spackle shield covering an opening. 
           [0038]      FIG. 12B  is a front perspective view of the panel of  FIG. 12A , around which drywall has been installed. 
           [0039]      FIG. 12C  is a front perspective view of the panel and drywall of  FIG. 12B , showing mesh tape. 
           [0040]      FIG. 12D  is a front perspective view of the panel and drywall of  FIG. 12C , where the mesh tape has been covered by spackle. 
           [0041]      FIG. 12E  is a front perspective view of the panel and drywall of  FIG. 12C , where the spackle shield has been removed to show the opening. 
           [0042]      FIG. 13A  is a perspective view of two structures in a building (e.g. walls or wall and ceiling), in which an opening has been cut to receive a panel assembly. 
           [0043]      FIG. 13B  is a perspective view of the two structures of  FIG. 13A , in which the panel assembly has been placed within the opening. 
           [0044]      FIG. 13C  is a perspective view of the two structures of  FIG. 13B , in which the approximated edges of the panel assembly and the wall have been finished to provide a superficially continuous junction. 
           [0045]      FIG. 14  is a rear view of the panel assembly of  FIGS. 13A-13C , showing a receiver and attachments. 
           [0046]      FIG. 15A  is a horizontal cross-section of a panel assembly and speaker component installed in a wall, where the component is seated to the assembly using magnets. 
           [0047]      FIG. 15B  is a horizontal cross-section of a panel assembly and switch component installed in a wall, where the component is seated to the assembly using a long bolt. 
           [0048]      FIG. 15C  is a horizontal cross-section of a panel assembly and light component installed in a wall, where the component is seated to the assembly using a detent. 
           [0049]      FIG. 15D  is a horizontal cross-section of a panel assembly and a generic component installed in a wall, where the component is seated to the assembly using friction surfaces. 
           [0050]      FIG. 16  is a perspective view of a panel assembly being formed by pouring a panel material into a mold. 
       
    
    
     DETAILED DESCRIPTION  
       [0051]    In  FIG. 2  a component mounting apparatus  200  generally includes a panel  210 , with opening  220  and panel  260  with opening  270 . It should be appreciated that while each bracket is sized and dimensioned to hold a specific component, the brackets could be identical to one another to create a “universal bracketing system” that can hold components of various sizes. 
         [0052]    Panel  210  and panel  260  are preferably substantially identical to one another in terms of shape, size, dimensions, and material, but can vary from one another without departing from the scope of the previous invention. Where the specification refers to only one panel in a figure, it is to be assumed that the other panel in the figure has the same features, unless otherwise stated. 
         [0053]    Panel  210  is a piece of gypsum board, wood, plastic, or other material (or combination of materials) sufficiently strong to support a speaker or other desired component between two studs of a wall, or joists in a ceiling, or other supports. Where plywood is used as the panel material, for example, the panel might be as thin as ¼″ (6.35 mm), but would more preferably measure at least ½″ (12.7 mm) or ⅜″ (19.05 mm). Preferred materials include wallboard, Medium Density Fiberboard (MDF), High Density Fiberboard (MDF), Acrylonitrile Butadiene Styrene (ABS), and other materials that closely match various characteristics of drywall. Multiple materials could be used, for example mixed in with one another, alternating, layered on top of one another, or a combination. Preferably, the material has equal moisture absorption and coefficient of thermal expansion as the surrounding wallboard, while having greater durability and strength for attaching heavy components directly to the panel. For example QuietRock® 525 could be a paneling material used where the wallboard comprises drywall. 
         [0054]    Panel  210  is typically about twenty inches (about 50 cm) to twenty-four inches (about 60 cm) wide, but other contemplated panels can have any other suitable dimensions, even for example, up to the size to replace an entire sheet of wallboard. Narrower panels are also contemplated, although they would likely not have a sufficient width to extend between wall studs or ceiling joists. Suitable panels would usually have a width of at least six inches (15.24 cm) or twelve inches (30.48 cm) greater than the spacing between studs, which allows the installer considerably greater flexibility in positioning the panel on the wall. Lateral wings (not shown) could be attached to the perimeter of panel  210  to extend the width for installations where the studs are spread apart at a greater distance from each other than normal. While panel  210  is shown as a substantially planar apparatus, panel  210  can be concave, convex, or any other shape to either match the shape of the wallboard, or to introduce a non-planar surface to the wallboard. 
         [0055]    Panels  210  and  260  are could be aligned along their top or bottom edges, aligned along a centerline, or could be arranged in a staircase fashion with a top edge aligned to a bottom edge. In  FIG. 2 , laser light  240  and an alignment indicator  290  are used to align panel  220  with panel  210  along a centerline marked by laser beam  242 . Alignment indicator  290  is shown as a line marked along a horizontal centerline of  270 , but could be any other suitable alignment indicator, including a series of marks in a row, an edge of panel  260 , or an edge of opening  270 . While the alignment indicator is generally a straight line, the indicator can be a curve or other shape, especially if the opening or bracket is not straight. Laser light  240  could also fan out a second line (not shown) that runs perpendicular to laser beam  242  to designate a second axis of alignment. One of ordinary skill in the art would appreciate that a second line could necessitate a second alignment indicator on panel  260 . Additionally, since lasers can fan out lines in multiple directions, a laser level could be used to align panels placed on different wallboards of a room. 
         [0056]    Hole primers  212 ,  262  are spaced approximately 1 inch (2.5 cm) from center, a diameter of 0.375 in (9.525 mm), and are approximately ¼ in (6.35 mm) deep, but can be shaped and configured in other suitable ways. A “hole primer” is a concave hole deepest in the center that helps an installer drill a screw or hammer a nail in a designated place without slipping. The diameter of the hole primer is preferably larger than the diameter of the screw head or nail head used so as to prevent the head of the screw or nail from leaving an unsightly bump on the surface of the wallboard after spackling. Other suitable receivers are contemplated, for example visual marks or pre-drilled and threaded screw holes. 
         [0057]    Each opening  220 ,  270  can also be of any suitable shape and size. Preferred openings are rectangular to accommodate common rectangular components, for example light switches, wall outlets, speaker volume controls, and home security systems. However, the openings could also be oval or circular or any other desired shape. The area of the opening is generally dependent on the size of the component, and can range up to 80 in 2  (about 520 cm 2 ) or larger. Especially preferred openings have an area of at least 20 in 2  (about 130 cm 2 ), 40 in 2  (about 260 cm 2 ), 60 in 2  (about 390 cm 2 ), and even 80 in 2  (about 520 cm 2 ). Nevertheless, for stability, it is contemplated that the panel would have openings with a length that is no more than half or one third the length of the panel. 
         [0058]    The openings  220  and  270  are shown to be identical in height, and are centered in each panel, but it should be appreciated that the openings need not have any shared dimensions, and could be positioned in any suitable arrangement relative to the panels  210  and  260 , respectively. Openings could be cut at a job site or elsewhere by an installer, but are more conveniently precut (or molded to include the opening) at the manufacturer. It is possible for a panel to have punch out openings or perhaps cutout lines to facilitate selection of the position of the opening at the job site, but those options are currently disfavored relative to a manufactured pre-cut or molded opening and a relatively large panel. 
         [0059]    Brackets  230 , and  280  are preferably sized and dimensioned to fit snugly into the openings  220  and  270 , respectively, but in any event are screwed, glued, clamped, or are otherwise securely attached to the panels  210  and  260 , respectively. The secure attachment is important since in at least some embodiments, the component housing will be attached to the bracket rather than being directly attached to the panel. The brackets are preferably molded from polyethylene or other sufficiently strong and durable thermoset plastic, and as shown in greater detail in  FIG. 8  bracket  280  includes holes  282  for screws (not shown), a recess  284  into which a component cover  914  can be removably secured via a holding mechanism, and a rim  280 A, and optional magnets  286  or an optional press fit (not shown). 
         [0060]    Spackle shields  224  and  274  preferably cover openings  220  and  270 , respectively, to prevent mud or drywall from entering the interior of the brackets, and can be removed after spackling. This is particularly helpful for when an electronic component is pre-installed behind the panel before spackling. Spackle shield  175  can have optional level  177  to help ensure that the panel is being installed horizontally. While level  177  is shown as a standard spirit level, any device that ensures that the panel is level is appropriate. Other devices that assist in installation can be provided in the spackle shield, for example a laser leveler to help align several panels with one another or a compartment that stores extra screws and magnets. 
         [0061]    The components mounted to brackets  150 ,  160 , and  170  can be any components mounted to a wall, for example speakers, plasma screens, in wall art panels, in wall cabinets, windows, wall outlets, security systems, fuse boxes, light switches, lighting, sprinkler systems, smoke detectors, and so forth. While the brackets and openings are generally shaped and sized to fit particular electronic devices, for example a rectangle for a light switch or a circle for a ceiling light, the universal brackets may be used that can accommodate a variety of electronic devices. To fit the component to a universal bracket, the component could consist of an outer casing that fits around the electronic device and couples to the universal bracket. 
         [0062]      FIG. 3  shows an alternative component mounting apparatus  300  with panel  310  and panel  360 . Similar to mounting apparatus  200 , panel  310  has opening  320 , bracket  322 , and spackle shield  324 , and panel  360  has opening  370 , bracket  372 , and spackle shield  374 . In the present embodiment, spackle shield  374  also has a level  375  that assists an installer level panel  360 . More importantly, panel  310  has protrusion  330  and recess  340  that interlock with recess  390  and protrusion  380  on panel  360 , much like dovetail joints. The interlocking edges of panel  310  and  360  not only help mate the two to one another, but also act as an alignment mechanism to help align the position of panel  310  with respect to panel  360 . Protrusion  330  and recess  390  are shaped differently than the other protrusions to ensure that the panels interlock in only one way. While adding one or more such “unique protrusions” is advantageous, ensuring that the panels interlock in only one way is not necessary. Indeed, in some situations it may be beneficial to the installer to use panels that can interlock in multiple ways, so as enable a small variety of alignment positions. 
         [0063]    When the edges are interlocked, the top and bottom edges of panel  360  are in line with the top and bottom edges of panel  310 . It is appreciated that different configurations of interlocking edges can bring the panels into other desirable coordinations relative to one another without departing from the scope of the present invention. Edges that “interlock” with one another can be sized and shaped to interlock directly with one another, or can have recesses that mutually receive a single peg, pin, screw, U-bar, or other similar device, as shown in  FIGS. 5-7 . 
         [0064]    The panels are aligned when the interlocking edges of the panels are approximated to one another. “Approximating” is defined herein to mean bringing the edges near or towards one another so that the junction or gap between the edges is less than 10 mm (0.394 in), 5 mm (0.197 in), or even 2 mm (0.079 in). Preferably, the panels are glued to one another before mounting onto the wallboard. The junction can also be taped and/or covered with a spackling compound to both join the panels and prevent the panels from skewing or misaligning. 
         [0065]    Interlocking protrusions and recesses do not have to be formed on the major planes of the panels. For example, in  FIGS. 4A and 4B , a component mounting apparatus  400  has panel  410  with a recess  420  and a panel  460  with a matching protrusion  470 . As shown more clearly in  FIG. 4A , the protrusions and recesses are cut are tongues and grooves instead of dovetails. All other suitable ways of forming interlocking edges are contemplated, including for example using matching snaps, butt joints, and mortise/tendons. 
         [0066]      FIGS. 5A and 5B  shows another alternative component mounting apparatus  500  that aligns panels  510  and  560  using recesses  520  and  570 , respectively, located on the backside of the panels. As U-bar  550  mates with recesses  520  and  570 , the panels are more accurately aligned. U-bar  550  is a bar with square-shaped pegs that interlock with recesses on both panels and holds the panels in alignment relative to one another. The pegs and recesses may be any suitable shape, but is preferably non-circular to prevent the pegs from twisting within the recess. Additionally, glue or matching indents/detents could be used to prevent U-bar  550  from slipping out of recesses  520  and  570 . While it is appreciated that recesses  510  and  560  could also be located on a front of the panels, it is preferred that the recess is on the back of the panel to prevent bulging on the front of the panel. Multiple sets of U-bars and recesses can be used to ensure that the panels do not fall out of alignment. 
         [0067]      FIGS. 6A and 6B  shows an alternative component mounting apparatus  600  that aligns panels using screws and screw-holes. An installer can abut the edges of panel  610  and panel  660  with one another while threading screw  650  through pocket hole  670  in panel  660  into screw-hole  580  in panel  610 . Pocket hole  670  is preferably sized and dimensioned such that when screw  650  is fully screwed in pocket hole  670 , the head of screw  650  does not protrude from the back surface of panel  660 . Multiple screws and pocket holes are preferred to help hold panel  610  in place against panel  660  and ensure that the panels do not fall out of alignment. 
         [0068]      FIGS. 7A and 7B  illustrates yet another alternative component mounting apparatus  600  with panel  610  and panel  660 , where the panels are aligned with respect to one another using pegs. An installer generally coats a wooden peg  650  with glue and inserts peg  650  into opposing recesses  620  and  670  in panels  610  and  660 , respectively. The location of the recesses determines how the panels are oriented with respect to one another. 
         [0069]    In  FIG. 8 , bracket  280  includes holes  282  for screws (not shown), a recess  284  into which a component cover  914  can be removably secured via a holding mechanism, and a rim  280 A, and optional magnets  286  or an optional press fit (not shown). The brackets are preferably molded from polyethylene or other sufficiently strong and durable thermoset plastic, but any material suitable for supporting the weight of a component can be used. 
         [0070]      FIG. 9  also shows a component  910  and a component cover  914 . Component  910  is shown having speaker  912 , but component  910  could be any practical component, including especially speakers, lights, air conditioners, or any other component that is typically larger than its external opening. The various wires for power and signal are not show in the Figures, but could be assumed, and can be those conventionally contemplated in the art. Component cover  914  can be any suitable grille, but is preferably a metallic mesh grille that press-fits into the opening  270 . Additionally or alternatively, the component cover can include a ferrous material that is attracted to magnets  286  in bracket  280 . 
         [0071]    As seen in  FIG. 10  the rim  280 A is sized and dimensioned to extend outwardly beyond a front of the panel  260  by a very small distance  281 , which provides a lip that can readily be used as a stop against which to spread a spackling compound, for example plaster or drywall. Preferred such distances  281  are less than ⅛ inch, and preferably about 1/16 inch, or in metric terms about 1-3 mm. Preferably, the panel has a thickness of at least ¼ inch (6.35 mm). Also shown in  FIG. 10  is an attachment member  288  that helps secure bracket  280  to panel  260 . A screw hole (not shown) can be provided in attachment member  288  to help affix bracket  280  to panel  260 . 
         [0072]    It should be appreciated that the rim could be separable from the panel. Thus, for example, the rim could be a separately molded piece of plastic, metal or composite that is installed into the opening by the installer, or at a factory. 
         [0073]    As seen in  FIGS. 11A and 11B , a bracket backing  1110  with screw holes  1112  could be used to clamp bracket  280  to panel  260 . In this embodiment, attachment member  288  fits within recess  114  on the front of panel  260  and bracket backing  1110  fits within recess  266  on the back of panel  260 . Screw  1114  threads through screw holes  282  and  1112 , and finally through nut  1116  to provide a clamping force around panel  260 . Clamping bracket  280  to panel  260  provides a secure connection without the need for expensive glues or adhesives. 
         [0074]    In  FIG. 12A , the panel  260  is affixed to two studs  1210 A,  1210 B in a wall, and screws  1215  are inserted through hole primers  262  and the panel  260  on the right side, and through an attached flange  264 . Panel  260  shows opening  270  with a spackle shield covering the bracket. Of course, the positioning and orientation of the panel could be varied in any suitable manner with respect to the studs,  1210 A,  1210 B, including moving the panel  260  higher or lower, left or right, or even tilting the panel clockwise or counterclockwise. Similarly, the studs should also be interpreted herein as emblematic of any support structures of a wall, whether or not such structures are technically considered to be studs. In addition, a greater or lesser number of screws could be used, or inserted in some other arrangement than that shown to provide greater or lesser support. The screws could also be replaced or supplemented by some other attachment means such as an adhesive. 
         [0075]    Those skilled in the art will appreciate that the combination of panel and bracket could be provided in several different ways. The panel and bracket could, for example, be joined together at a job site, and indeed the panel could even be “manufactured” at the job site by cutting or punching out the opening. More preferably, however, the panel and bracket are provided as an item of manufacture to the installer by a supplier or manufacturer. The rim of the panel can be pre-installed to the panel. Thus, in various embodiments a kit could contain one or more of a panel, a bracket (or at least a rim around the edges of an opening in the panel), a speaker housing, a spackle shield, and installation screws. The installer would then provide whatever labor is appropriate for the installation, including optionally installing the bracket and/or rim, optionally installing the spackle shield, and optionally mounting the speaker into the speaker housing to the back side of the panel. It is also contemplated that the speaker can be pre-installed into the panel before installation. Alternatively the combination of the panel and bracket can be mounted before installing a rim on the opening. 
         [0076]    In  FIG. 12B  drywall  1220  or other wallboard has been installed on all four sides around the panel  260 , and coupled to the wings using screws  1215 . Where wings are present, as in the embodiment depicted, the drywall  1220  overlays the wings, but the wings are sufficiently thin so that the drywall is not noticeable raised. Those skilled in the art will appreciate that although  FIG. 12B  shows the drywall  1220  surrounding the panel  260  as a single piece, it is entirely possible that the drywall could comprise multiple pieces (not shown). It is also contemplated that installation of the drywall  1220  might be delegated to a drywaller or other tradesman distinct from the panel installer. Nevertheless, the process of installing the panel on one or more wall supports is deemed to include the step of positioning the panel so that it can be approximated in an end-to-end fashion by a piece of wallboard or other wall section. 
         [0077]    In  FIG. 12C  mesh tape  1230  is applied along the juxtapositions or other approximations between edges of the panel  260  and edges of the drywall  1220 . Here again, this step is usually delegated to a professional drywaller, but could be accomplished by the installer of the panel, regardless of which person actually does the work. 
         [0078]    In  FIG. 12D  the mesh tape is covered by a spackling compound, and is ready for painting, wallpapering, or other surface coating. Preferably, the spackling compound is smoothed over the entire front surface of the panel to the lips of opening  270 . As used herein, the terms “spackle” and “spackling” should be interpreted as broadly as possible, to include for example plaster and plastering of any type. One objective is to provide a smoothed out surface that completely or substantially hides the joints between edges of the panel and edges of the drywall 
         [0079]    In  FIG. 12E , the spackle shields are removed from openings  270  and components can be installed in the new uniform wallboard  1230 . 
         [0080]    In  FIG. 13A  an installation  1300  generally includes wallboards  1310 ,  1320 , an opening  1314  on structure  1310 , and a panel assembly  1330  comprising at least two interconnected panels  1332  and  1336  that will installed into the space  1314 , as shown by arrow  1340 . 
         [0081]    As used herein, the term “assembly” means a group of objects that have multiple components or functional portions. Thus, the term comprises: (a) multiple pieces that are coupled together in some manner, either temporarily or permanently; and also (b) a single molded object with multiple functional components. 
         [0082]    In typical installations, the wallboards  1310 ,  1320  would be adjacent vertical walls, or a vertical wall and a ceiling, and  FIG. 13A  should be interpreted to include all such embodiments. Thus, for example, where wallboards  1310 ,  1320  are interpreted to be vertical walls, members  1312 ,  1322  could be studs. Where wallboard  1310  is interpreted as a ceiling, members  1312  could be joists, and members  1322  could be horizontal struts. Although the portions of the wallboards  1310 .  1320  depicted in the figure as substantially flat, those skilled in the art will appreciate that the structures could be curved, or have curved portions. In addition, those skilled in the art will appreciate that wallboard  1310  could exist independently of wallboard  1320 . 
         [0083]    Wallboards  1310 ,  1320  would typically comprise drywall, which term is used herein generically to include all manner of wallboard, fiberboard, gypsum board, GWB, plasterboard, Sheetrock® and Gyproc®, and so forth. Additionally or alternatively, wallboards  1310 ,  1320  could comprise other materials, including for example polymers, masonry, ceramics, and acoustic ceiling tile materials or other composites. 
         [0084]    Wallboards  1310 ,  1320  can have any suitable dimensions, from only a few square feet or less, to hundreds of square feet or more. Wallboards  1310 ,  1320  will usually, however, have relatively small thicknesses of between ¼″ and 1″ in thickness. 
         [0085]    Panel assembly  1330  can be produced at a job site, for example, by interlocking two pre-fabricated panels with brackets, preferably before the assembly is inserted into the wallboard space  1314 . The panels could be glued together to prevent the panels from unlocking from one another. While the assembly is shown as one piece in  FIG. 13A , it is to be appreciated that an assembly can be made of two panels that are not directly connected to one another, and are instead aligned at a distance using a laser light. 
         [0086]    As discussed above with respect to  FIGS. 2-12 , the openings  1334 ,  1338  of  FIG. 13A  can be any suitable size, shape, or number. As currently contemplated, it is desirable that the total front facing area consumed by the openings be relatively small with respect to that of the panels  1332 ,  1336 . That ratio is preferably at least 3, more preferably at least five. Viewed from another perspective, it is preferred that the panels  1332 ,  1336  extend in at least one direction at least 3 inches (7.62 cm) from the closest edge of the openings  1334 ,  1338 , respectively for light or other simple switches, electrical outlets and so forth, and at least 5 inches (12.7 cm) for lights, more complicated switches and other controllers, speakers and so forth. Where the component has a front-facing surface area of at least 25 in 2  (about 160 cm 2 ), the panels  1332 ,  1336  extend in at least one direction at least 12, 18, or even 24 inches (about 30, 45, or 60 cm) from the closest edge of either opening  1334  or  1338 . 
         [0087]    In  FIG. 13B  the panel assembly  1330  has been placed within the space  1314 . There will almost always be some gap between the edges of the panel assembly  1330  and those of the surrounding structural component  1310 , ranging in typical installations from zero (where the panel assembly  1330  is abutted against the structural component  1310 ), and perhaps 1/13″ (3.175 mm) to ¼″ (6.35 mm). Indeed, there will almost always be multiple different gaps around the edge of the panel assembly. Where the workmanship is sloppy, or the project is especially difficult, the gap in some sections can be larger. In addition, it is contemplated that an intermediate member (not shown), as for example a paper, shim, or even a frame can be installed in the gap between the panel assembly  1330  and the structural component  1310 . As long as the edges of the assembly and the structure are somewhat near each other, and the gap can be finished and concealed such that an at least superficially continuous junction is established between them, the edges are considered to be approximated. 
         [0088]    In  FIG. 13C  the approximated edges of the panel assembly and the structure have been finished to provide an at least superficially continuous junction. As used herein the term “at least superficially continuous junction” refers to a junction that appears to casual observation to be seamless. By way of example, a good workman-like job in taping and plastering adjacent sections of wall board is considered herein to produce an at least superficially continuous junction, especially where subsequent painting or wallpapering eliminates any seam apparent to casual observation. 
         [0089]    In  FIG. 14  a rear view of the panel assembly  1330  of  FIGS. 13A-13C  shows a receiver  1410  and attachments  1420  of the receiver to the panel  1332 . The receiver  1410  in this instance is an open box, but all manner of alternative receivers are also contemplated. For example, receivers could be tubular or have some other shape, could be completely or partially closed, could be larger, smaller, or the same size as the opening, and can have punch outs such as those found on a typical electrical connection box. An exemplary receiver made to accept an electrically powered component could have electrical connections that mate with electrical connections on the component as the component is pushed into the receiver. Preferably, the electrical connections both power the component, and connect the component to other electrical devices. 
         [0090]    The attachments  1420  are shown as four wings, extending from the four sides of the receiver  1410 , and then glued, nailed, stapled or otherwise affixed to the panel  1332 . Those skilled in the art will appreciate that still other methods could be used, including forming the panel  1332  around the wings or attaching the receiver to a bracket on panel  1332 . Still further, it is contemplated that wings could be eliminated altogether. In a ¾″ or 1″ thick fiberboard, for example, a collar pressed into the opening, or used as a form around which the fiberboard is made, might have sufficient strength to hold a relatively lightweight component. 
         [0091]      FIGS. 15A-15D  depict alternative mechanisms for coupling and/or locking various components  1561 - 1564  within receivers  1410 . In  FIG. 15A  the mechanism comprises magnets  1572  that lock to a magnetic portion of component  1561 . The component can then be removed from the receiver by attaching a stronger magnet to component  1561 , and pulling component  1561  away from magnets  1572 . In  FIG. 15B , the mechanism comprises a long threaded bolt  1574 A that is turned into a nut  1574 B. In  FIG. 15C  the mechanism comprises detents that fit within biasing members  1576 B. In  FIG. 15D  the mechanism comprises a compressible polymer or fabric that fits in the gap between the rear portion  1564 B of the component  1564 , and the receiver  1410 . In this particular example, the facing plate  1564 A of the component  1564  is larger across than the rear portion  1564 B. 
         [0092]    In the Figures component  1561  is a speaker or other speaker assembly  1561  A, component  1562  is a light or other switch, (showing toggle  1562 A), component  1563  is a light, light fixture or other light assembly, and component  1564  is a generic component that could euphemistically be viewed as an electrical outlet, or any other reasonably installable component. Of course, the combinations expressly depicted in the Figures are merely examples, and thus it should be appreciated that one could combine any of the components  1561 - 1564  with any of the depicted seating mechanisms, or indeed any suitable seating mechanism. 
         [0093]      FIGS. 15A-15D  also demonstrate that the face of the components are only optionally made completely flush with the face of the panel  1332  when they seat with the receiver  1410 .  FIG. 15D , for example, shows a face portion  1564 A that is recessed from the face of the panel  1332 . Here, those skilled in the art will appreciate that the recess is exaggerated to assist visualization. In practice, any such recess or extension would likely be less than ⅛ th  inch (3.175 mm). Furthermore, it is contemplated that the components can be easily removed by extraction tools, such as a screwdriver and the like, to provide for simpler change of installation. 
         [0094]      FIG. 16  is a perspective view of a panel assembly  1610  being formed by pouring a panel material from container  1640  into a mold  1620 . This process brings the poured material right up against the frame portion that defines the opening  1630 , regardless of any irregularity or other difficulties with the shape of the opening. All manner of panel materials are contemplated, including for example curable plastics, and masonry composites. 
         [0095]    Thus, specific embodiments and applications of flangeless speaker devices and methods have been disclosed. It should be apparent to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims. Moreover, in interpreting both the specification and the claims, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced. Where the specification claims refers to at least one of something selected from the group consisting of A, B, C . . . and N, the text should be interpreted as requiring only one element from the group, not A plus N, or B plus N, etc.