Abstract:
A recessed in-wall interface box assembly that is relatively easy to install in a finished wall, including accommodations for video and electrical wiring in the box, having an attractive appearance, and that is relatively simple and inexpensive to manufacture.

Description:
RELATED APPLICATIONS  
       [0001]     This application claims the benefit of U.S. Provisional patent application 60/823,896, filed Aug. 29, 2006, entitled IN-WALL INTERFACE AND MOUNTING METHOD FOR DISPLAY MOUNT. The above referenced application is incorporated herein by its entirety by reference. 
     
    
     FIELD OF THE INVENTION  
       [0002]     The present invention relates to video displays and more specifically to mounting devices for video displays.  
       BACKGROUND OF THE INVENTION  
       [0003]     Flat panel monitors and televisions are becoming ever-more popular in homes and in commercial settings. Previously common Cathode-Ray Tube (“CRT”) monitors are being replaced by flat panel devices at a rapid rate. A chief advantage of flat panel devices over CRTs is the appealing aesthetic of a very shallow device that resembles a framed photo or painting when mounted on a wall.  
         [0004]     Many different configurations of wall mounting devices have been developed for flat panel displays. Examples of such prior mounting devices are disclosed in U.S. Pat. Nos. 7,028,961; 6,905,101; D507,477; D496,367; D495,714; D495,713; D494,978; D494,596; D493,800; and U.S. Patent Publication No. 20070158515 all hereby incorporated herein by reference. Although these prior mounting devices contribute to providing a shallow frame aesthetic for the wall mounted flat panel monitor, some clearance between the back of the monitor and the plane of the wall is generally needed with these prior art mounts in order to provide space for the mount itself and to allow for positioning of the monitor.  
         [0005]     In-wall recessed boxes have been previously used with a flat panel monitor and mounting device to enable the back plane of the monitor to be positioned closer to the plane of the wall on which it is mounted. In these devices, the box is installed in the wall to define a recess and a mounting device, such as those referenced above, is mounted in the recess. These previous in-wall boxes, however, have had some drawbacks. One drawback of previous in-wall boxes is that they are generally difficult to install in an existing finished wall, requiring extensive portions of the wall inner envelope layer (i.e. sheetrock or plaster) to be removed to facilitate access for fastening the box to structural frame members (i.e. studs). Due to variations in the spacing of studs, specialized shims are often needed to enable positioning of the in-wall box at a desired location in the wall. Another installation related drawback to prior in-wall mounting devices is that no provision is typically made to accommodate electrical and video wiring within the box. Separate outlet boxes must be provided in the wall adjacent the in-wall mounting box or holes must be drilled in the box for the wires to be accommodated. Also, the appearance of prior boxes has typically been somewhat crude, having a generally “industrial” character. Finally, the boxes themselves have typically been expensive to manufacture.  
         [0006]     What is still needed in the industry is an in-wall interface in the form of a recessed in-wall box that is relatively easy to install in a finished wall, has accommodations for video and electrical wiring in the box, has an attractive appearance, and that is relatively simple and inexpensive to manufacture.  
       SUMMARY OF THE INVENTION  
       [0007]     The present invention addresses the need in the industry by providing a recessed in-wall box that is relatively easy to install in a finished wall, has accommodations for video and electrical wiring in the box, has an attractive appearance, and is relatively simple and inexpensive to manufacture.  
         [0008]     An embodiment of the present invention generally includes an in-wall interface for a display mount that includes a body pan defining a recess for receiving a display mount for flat panel display devices. The body pan is sized for positioning between a pair of frame members of a wall structure. The interface also includes at least one shimming mechanism operatively coupled with the body pan, the shimming mechanism being selectively shiftable to engage the frame members and retain the body pan in a desired position. Further, the shimming mechanism includes at least one fastener for permanently affixing the in-wall box to the frame member.  
         [0009]     Additionally, another embodiment of the present invention includes an in-wall interface for a display mount. The interface includes a body pan defining a recess for receiving a display mount for flat panel display devices. The body pan is sized for positioning between frame members of a wall structure. Also, found in some embodiments are multiple threaded bosses defined in the body pan walls at locations in the same proximity as the frame members. Further, a plurality of externally threaded shimming thumb-screws may be included. These thumb-screws are capable of engagement through the threaded bosses for adjustable support of the body pan between the structural frame members. The shimming thumb-screws each contain an axially disposed bore. A plurality of fasteners are provided for driving through the bores of the shimming thumb-screws and into the structural frame members to fixedly support the body pan.  
         [0010]     A further embodiment of the present invention includes a method of installing a flat panel display mount. The front panel display is installed using this method by first providing an in-wall interface member defining a recessed portion for receiving a display mount and accommodating video and electrical wiring. A hole is defined in a membrane assembly of a wall roughly corresponding to the shape of the periphery of the in-wall interface member. Shimming thumb-screws are threaded through bosses in the in-wall interface until the distal end of each thumb-screw engages a frame member in the wall.  
         [0011]     Some additional embodiments provide an in-wall interface system for mounting an electronic display including a body pan that defines a recess for receiving a display mount for flat panel display devices. The body pan is sized for positioning between a pair of frame members of a wall structure. The interface system also includes at least one means for shimming operatively coupled with the body pan. The shimming means is selectively shiftable so that it engages a surface of the frame members to retain the body pan in a desired position. Also included in the shimming means is at least one fastening means.  
         [0012]     An embodiment of the present invention includes an in-wall interface system for mounting an electronic display. This embodiment includes a system including a body pan defining a recess for receiving a display mount for flat panel display devices. The body pan is sized for positioning between a pair of frame members of a wall structure and includes opposing walls providing a plurality of externally threaded bosses. There is also at least one shimming mechanism operatively coupled with the body pan. The shimming mechanism is selectively shiftable within the bosses to engage the frame members to retain the body pan in a desired position. Also, the shimming mechanism includes at least one fastener.  
         [0013]     An advantage of certain embodiments to provide an in-wall interface which may be installed without requiring excessive removal of sheetrock or other inner wall envelope layer.  
         [0014]     An advantage of certain embodiments is to provide an in-wall interface which is relatively easy to install and which does not require use of additional specialized shims.  
         [0015]     It is also an advantage of certain embodiments to accommodate electrical and video wiring within an interface box as well as to eliminate the need for separate adjacent outlet boxes.  
         [0016]     An advantage of certain embodiments is to provide an in-wall interface system for mounting an electronic display which has an attractive and aesthetically pleasing appearance, yet which is inexpensive to manufacture.  
         [0017]     Further objects and advantages of particular embodiments of the present invention may become apparent to those skilled in the art upon review of the figures and descriptions of the present invention herein. 
     
    
     BRIEF DESCRIPTION OF THE FIGURES  
       [0018]     The invention may be more completely understood in consideration of the following detailed description of various embodiments of the invention in connection with the following drawings, in which:  
         [0019]      FIG. 1  is a front perspective view of an in-wall box according to an embodiment of the present invention, depicted in a frame wall;  
         [0020]      FIG. 2  is a cross-sectional view of the in-wall box of  FIG. 1  taken at section  2 - 2  of  FIG. 1 ;  
         [0021]      FIG. 3  is a phantom view of a shimming thumb-screw for use in the in-wall box of the present invention.  
         [0022]      FIG. 4  is an end view of the shimming thumb-screw of  FIG. 3 ;  
         [0023]      FIG. 5  is a perspective view of the shimming thumb-screw of  FIGS. 3 and 4 ;  
         [0024]      FIG. 6  is a perspective view of an installed in-wall box depicted with the display mounting device in place and coupled with a flat panel electronic display;  
         [0025]      FIG. 1   a  is a front perspective view of the body pan of an in-wall box according to an embodiment of the invention;  
         [0026]      FIG. 2   a  is a front elevation view of the body pan depicted in  FIG. 1   a;    
         [0027]      FIG. 3   a  is a first side elevation view of the body pan depicted in  FIG. 1   a;    
         [0028]      FIG. 4   a  is a bottom plan view of the body pan depicted in  FIG. 1   a;    
         [0029]      FIG. 5   a  is a top plan view of the body pan depicted in  FIG. 1   a;    
         [0030]      FIG. 6   a  is a rear elevation view of the body pan depicted in  FIG. 1   a ; and  
         [0031]      FIG. 7   a  is an opposing side elevation view of the body pan depicted in  FIG. 1   a.   
     
    
       [0032]     While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.  
       DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0033]     There is generally depicted in  FIGS. 1-7   a  an in-wall interface for flat panel display and mounting system  20  in a wall structure  22 , that includes a membrane assembly  24 , for example sheetrock or plaster, and frame members  26 , which may be wood studs. Such wall structures  22  having spaced-apart parallel frame members  26  are typical in most residential and commercial buildings. Mounting system  20  generally includes in-wall interface  28 , which receives display mount  30  and attached flat panel display device  32 .  
         [0034]     In-wall interface  28  generally includes body pan  34 , shimming mechanisms in the form of shimming thumb-screws  36 , and threaded fasteners  38 . Body pan  34  has walls  40  and back  42  defining recess  44 . The depth of recess  44  and back  42  are sized such that the body pan will conveniently reside within the space between the membrane assembly  24  and any interior walls or structures. Peripheral flange  46  may extend outward around periphery  48  of recess  44 , to enable hiding of wall membrane edges  50  for a finished appearance when installed in the wall structure  22 . The peripheral flange  46  may have outer rounded corners and extend away from the periphery  48  in all directions. Body pan  34  may be molded from polymer in a single, integral piece or may be made from any other suitable material such as metal. Rounded corners  52  and  54  may be provided for a pleasing aesthetic appearance and to facilitate molding from the polymer material. Further, such contoured features can aid in minimizing entanglement of cords and avoid damage caused by sharp edges or corners.  
         [0035]     Bosses  56  are provided in various locations in the walls  40  to allow convenient and beneficial adjustment locations for supporting and aligning the body pan  34  with the surrounding frame members. The bosses are generally part of the body pan  34 . Typically, the boss locations are as shown in the figures, where pairs of bosses are transversely located in parallel walls across the recess of body pan  34  in axial alignment with one another. Further, the plurality of bosses  56  are spaced at varied distances from the periphery  48  of the body pan on the walls  40  to provide a greater range of potential adjustments for aligning or spacing the body pan  34  with respect to the frame members  26 . Also, such spacing distributes stresses across the frame members  26  and allows for enhanced stability and desirable interface weight distribution. Although bosses  56  are typically located in the two side walls  40  of the body pan  34  that run parallel to vertically extending frame members  26 , it is also contemplated that bosses  56  may be located in other walls  40  when frame members are adjacently disposed and therefore allow for this possibility.  
         [0036]     The bosses  56  are provided in walls  40 , each defining a threaded bore  58  for receiving one of shimming thumb-screws  36 , each of which has cooperating exterior threading  60 . Each of the shimming thumb-screws  36  are thereby enabled to be threaded in and out of bores  50 . Each shimming thumb-screw  36  defines an axially aligned bore  62  for receiving a fastener  38 . Such fasteners  38  have a length greater than that of the corresponding shimming thumb-screws  36  so that the fasteners  38  may protrude from both ends of the shimming thumb-screws  36  when inserted in bore  50 , as shown in  FIG. 2 . Bore  62  may or may not threadedly engage with fastener  38 .  
         [0037]     To install in-wall interface  28 , a hole may be cut in membrane assembly  22 , roughly corresponding with the size and shape of periphery  48 . In-wall interface  28  is then placed in the hole, and each shimming thumb-screw  36  is threaded into one of the bosses  56  until distal end  64  engages the surface frame member  26 . It will be appreciated that each shimming thumb-screw  36  may be separately adjusted to obtain the desired positioning of in-wall interface  28  within the hole, for example to adjust sideways positioning and to ensure that in-wall interface  28  is square with the floor ceiling or nearby wall edges. It will also be appreciated that in certain embodiments, the tip of thumb-screw  36  may be pointed so as to sink slightly into the surface of the frame member in order to provide greater purchase between the thumb screw and the frame member. Once shimming thumb-screws  36  are tightened in the desired position to temporarily hold the in-wall interface  28  in place, fasteners  38  are driven through bores  62  to secure in-wall interface  28  to the frame members  26 .  
         [0038]     In an embodiment of the invention, knockout portions  66 ,  68 , may be provided in one or more of walls  40  to facilitate electrical connections, such as duplex outlet  70 , thereby enabling a pleasing finished appearance to the electrical wiring installation for flat panel display  32 . These knockout portions may, for example, be used to accommodate wiring for auxiliary components such as DVD players, receivers, speakers or other input or output devices.  
         [0039]     It will be appreciated that, in alternative embodiments, shimming thumb-screws  36  may extend from only one of the walls  40 , with the opposing wall  40  directly engaged with the adjacent frame member. In other embodiments, bosses  56  may be omitted and thumb-screws  36  threaded through apertures that are either pre-defined in body pan  34  or that are drilled in desired locations just before installation. In further embodiments, fasteners  38  may be separate from thumb-screws  36 , with fasteners  38  being driven through separate apertures defined in walls  40 .  
         [0040]     What is provided then is an easy to install, discrete, and aesthetically pleasing in-wall interface for receiving and partially concealing a flat panel display mount in which accommodations for video and electric wiring are provided as well as sufficient space for flat panel monitor adjustment.  
         [0041]     The embodiments above are intended to be illustrative and not limiting. Additional embodiments are encompassed within the scope of the claims. Although the present invention has been described with reference to particular embodiments, those skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention. For purposes of interpreting the claims for the present invention, it is expressly intended that the provisions of Section 112, sixth paragraph of 35 U.S.C. are not to be invoked unless the specific terms “means for” or “step for” are recited in a claim.