Abstract:
A device for more reliable and rapid securing to or within a component. The device incorporates therein or independently uses a substantially flexible member to secure the device within the component.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
   This application claims priority from U.S. Provisional Application No. 60/636,647, filed Dec. 17, 2004 and incorporated herein by reference in its entirety. 

   BACKGROUND OF INVENTION 
   The invention is directed to the fastening field, particularly to the mounting of devices within a component. An electrical work box is a receptacle, generally of metallic or of thermoplastic composition, designed to support an electrical device. The electrical device may be a switch or plug receptacle in single, dual or multiple “gang” configurations, a lighting fixture, a ceiling fan, a speaker, or an alarm. The electrical work box may also provide wiring junctions for electrical applications, such as low voltage applications associated with audio/visual devices, telephone devices and computer networking devices. 
   In new construction, electrical work boxes are generally mounted to exposed studs or framing elements using nails or screws. In existing construction, electrical work boxes may be affixed to existing walls, including wallboard, lathe and plaster or other wall surfaces that have been mounted over framing. Such boxes are commonly referred to as old work boxes. 
   Old work boxes may include pressure/spring retaining latches. The latches are usually vertically and/or horizontally mounted to the exterior sides of the boxes and allow the box to be pushed through a wall opening. Once through the opening, the latches deploy by spreading beyond the rear edge of the wall opening. Pawls, commonly referred to as ears, wings, or fingers, are mounted on two or more opposing corners of the electrical work box. When deployed by means of a tightening screw, the pawls, in conjunction with opposing flanges integrally mounted on the front edges of the box, serve to clamp the box to the wall. 
   The retaining mechanisms employing latches and pawls often fail to securely mount the old work boxes in place. Where wall thickness varies, a thicker than typical wall may preclude pressure/spring retaining latches from expanding. A thinner than normal wall may result in space between the retaining latch and the rear wall surface and allow the box to move back and forth within the wall. Irregularities in the posterior wall surface in lathe and plaster walls or in insulating materials may also prevent pressure/spring retaining latches and/or screw activated pawls from properly deploying. 
   Further, in mounting electrical boxes using screw activated pawls, deployment of the pawls may over tighten the screw, resulting in stripping the threads in the pawl. As a result, the box must be dismounted and discarded and installation must be started over with a new box. 
   In view of the above difficulties, there is a need for a more reliable, quicker to use, and more versatile fastening system for electrical work boxes. 
   BRIEF SUMMARY OF THE INVENTION 
   The needs of the invention set forth above as well as further and other needs and advantages of the present invention are achieved by the embodiments of the invention described herein below. 
   According to one aspect of the invention, a device includes a structure having at least one outer flange, a substantially flexible member with an outer portion, an inner portion, and a rigid region, and a locking mechanism capable of being coupled to the substantially flexible member to secure the container to a component. The container may be made of a metal, a thermoplastic material, or a thermoset material. 
   In one embodiment of the invention, the device may be an electrical work box and the structure may be a container. In a certain embodiment, the rigid region may be an inner flange, which may be located at the inner portion of the substantially flexible member. In another embodiment, the locking mechanism may be integral with the container. In a further embodiment, the container may include at least one side channel. In an additional embodiment, the rigid region may lie between the outer and the inner portion of the substantially flexible member and the substantially flexible member may be coupled to a rigid channel at the rigid region. In certain embodiment, the rigid region may be integral with the substantially flexible member. 
   In a further embodiment, the inner portion of the substantially flexible member may be coupled to the container. In a still another embodiment, the substantially flexible member may be integral with the locking mechanism. In a still further embodiment, the substantially flexible member may be a cable tie. 
   In a still further embodiment, the substantially flexible member may include at least one groove. The locking mechanism may include a flap with an edge complementary to the groove. 
   In another aspect of the invention, a method for mounting a structure to a component includes inserting a substantially flexible member through an opening within the component, further through an opening in a portion of the structure of a device and through a locking mechanism, inserting the structure into an opening in the component, and pulling the substantially flexible member through the locking mechanism until a rigid region of said substantially flexible member is coupled to a surface of the component and an outer portion of the substantially flexible member is engaged with the locking mechanism. 
   In an embodiment of the invention, the device may be an electrical work box an the structure may be a container. In another embodiment, the method may include resting an outer flange on an outer surface of the component and further include engaging a flap of the locking mechanism with a recess in the outer portion of the substantially flexible member. The recess may be a groove or an opening. 
   In a further embodiment of the invention, the method may include creating an opening in the component where the component maybe a wall, a ceiling, or a floor or the like, and the electrical box may be replaced by a variety of devices which need to be inserted within the component and secured thereto. 
   In additional embodiments of the invention, the locking mechanism may be integral with the substantially flexible member or integral with the container. 
   In a certain embodiment of the invention, the rigid region may lie between the outer portion and an inner portion of the substantially flexible member. The rigid region may be integral with the substantially flexible member or may be coupled to a rigid channel at the rigid region. In another embodiment of the invention, an inner portion of the substantially flexible member may be coupled to the container. In a still further embodiment of the invention, the substantially flexible member may be transportable through the locking mechanism in a single direction. 
   According to an additional aspect of the invention, a device includes a structure having at least one outer flange, a substantially flexible member with an outer portion and an inner portion, and a locking mechanism capable of being coupled to the substantially flexible member to secure the container to a component. 
   In a certain embodiment of the invention, the device may be an electrical work box and the structure may be a container. In a further embodiment, the substantially flexible member may include at least one region of substantially reduced thickness. 
   In an additional aspect of the invention, a fastening system for use in securing a device within a component includes a substantially flexible member that includes an outer portion, an inner portion, and a rigid region, and a locking mechanism capable of being coupled to the substantially flexible member in order to secure said structure to the component. 
   For a better understanding of the present invention, together with other and further objects thereof, reference is made to the accompanying drawings and detailed description and its scope will be pointed out in the appended claims. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1A  is an illustration of an exploded view of an embodiment of the present invention, including a pair of substantially flexible members with solid flanges and separate locking mechanisms, which secure an electrical work box to a component; 
       FIG. 1B  is an illustration of an exploded view of an embodiment of the present invention, including a pair of substantially flexible members with hollow flanges, which secure an electrical work box with integral locking mechanisms to a component; 
       FIG. 2A  is an illustration of a side view of an embodiment of the present invention, including a substantially flexible member, containing a rigid region comprising a rigid channel; 
       FIG. 2B  is an illustration of a side view of an embodiment of the present invention, including a substantially flexible members, containing a rigid region integral with the substantially flexible member; 
       FIG. 3A  is an illustration of a side view of an embodiment of the present invention, including a substantially flexible member, containing a rigid region where a locking mechanism is integrated into the container by insertion and the flexible member is integral with the locking mechanism; 
       FIG. 3B  is an illustration of a side view of an embodiment of the present invention, including a substantially flexible member, containing a rigid region where a locking mechanism is integral with the container and the substantially flexible member is coupled to the container; 
       FIG. 4A  is an illustration of an embodiment of the present invention, which shows a side view of pre-deployment and post-deployment of rigid regions where the rigid region is a solid inner flange; 
       FIG. 4B  is an illustration of an embodiment of the present invention, which shows a top view of pre-deployment of rigid regions where the rigid region is a solid inner flange; 
       FIG. 4C  is an illustration of an embodiment of the present invention, which shows a bottom view of post-deployment of rigid regions where the rigid region is a solid inner flange; 
       FIG. 4D  is an illustration of an embodiment of the present invention, which shows a side view of pre-deployment and post-deployment of rigid regions where the rigid region is a hollow inner flange; 
       FIG. 4E  is an illustration of an embodiment of the present invention, which shows a side view of pre-deployment and post-deployment of rigid regions where the rigid region includes a rigid channel coupled to a flexible member; 
       FIG. 5  is a process flow diagram illustrating one method for mounting a device to a component; 
       FIG. 6  is an illustration of an embodiment of the present invention, which shows a pre-deployment of a substantially flexible member including four rigid regions; 
       FIG. 7A  is an illustration of an embodiment of the present invention, which shows a pre-deployment of a substantially flexible member, which is substantially uniform; 
       FIG. 7B  is an illustration of an embodiment of the present invention shown in  FIG. 7A , which shows a post-deployment of the substantially uniform, substantially flexible member; 
       FIG. 8A  is an illustration of an embodiment of the present invention, which shows a pre-deployment of a substantially flexible member including notches; and 
       FIG. 8B  is an illustration of an embodiment of the present invention shown in  FIG. 8A , which shows a post-deployment of the substantially flexible member including notches. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   Embodiments of the present invention provide a fastening system that may more quickly and more reliably mount devices such as electrical work boxes to components such as walls, ceilings, and floors than by the means currently represented by the prior art systems described above. The fastening system includes at least one substantially flexible member that contains a shaft or ribbon with depressions, that is, recesses or grooves, separated by teeth, molded or embossed into the ribbon. Rigid regions such as preformed securing mechanisms, including rigid flanges located at the ends of the substantially flexible members, or self-formed securing mechanisms, including rigid elements located at an interior position of the substantially flexible members, engage the rear surface of the component such as a wall. Pulling of the substantially flexible member through a likewise conventional locking mechanism causes the device to be held in position against a component. In the case of a rigid element, pulling of the substantially flexible member through the locking mechanism results in a buttress structure, which provides the support for the device against the component. 
   The fastening system of the present invention, using substantially flexible members, allows for quicker and more reliable installation than does the existing system employing screw activated pawls. No hand tightening of screws is necessary and there may be less interference from obstructions. The flexible member fastening system accommodates a wide range of component thicknesses and is less prone to over tightening, as an installer of the electrical work box is more aware of applying an excess of tension to the substantially flexible member than an excess of torque to a screwdriver in prior art electrical work box fastening systems. 
     FIG. 1A  illustrates an embodiment of the invention for installation in an existing component  150 , such as a wall, a ceiling, a floor, etc. An electrical work box  200  includes a structure, in this case, container  210 , one or more substantially flexible members  215 , and one or more locking mechanisms  220 . The container  210  may be made of a metal, thermoplastic material, or thermoset material and contains two outer flanges  110  integrated into the front surface  230  of the container  210 . The container may be a receptacle. As with all embodiments of the present invention, the use of the terms electrical box and wall is provided for a clear understanding of the invention, although other devices which find use inserted or fastened within a component may also be considered part of the present invention. 
   Two outer flanges  110  are incorporated, often integrally molded, into opposite corners of the electrical work box  200  and prevent the electrical work box  200  from migrating posterior through an opening  160  cut in a component  150  with a front surface  152  and a rear surface  154  to accommodate the electrical work box  200 . The outer flange  110  may contain a hole  225  that may accommodate a substantially flexible member  215 . A single outer flange  110  may completely coincide with the front surface  230  of the container  210 . An opening in the completely coinciding outer flange  110  may be square, as in this representation, or round. The locking mechanism  220  may be set into a recessed hole  270  in the outer flange  110  ( FIG. 1B ). 
   The substantially flexible member  215  has an inner region  240  and an outer region  242 . The substantially flexible member  215  may be fabricated from nylon or other thermoplastic materials and may include a generally flat extruded shaft or ribbon  217 , where recesses  219 , such as grooves or holes, may be integrated along one surface  218  of the ribbon  217 . 
   The locking mechanism  220 , separate ( FIG. 1A ) or incorporated into the container  210  ( FIG. 1B ), allows the ribbon  217  to be drawn through in only one direction, locking in each recess  219  until a desired maximum tightness is achieved. The locking mechanism  220  may include an internal flap  222 , possibly square in shape, which may extend approximately half way down an open central channel  224  to accommodate, in a complementary manner, the recess  219  of the substantially flexible member  215  and may be angled so that the substantially flexible member  215  can only be drawn one way, locking onto a recess  219  and preventing retraction. If the dimensions of the hole  225  exceed the dimensions of a cross section of the flexible member  225  where the locking mechanism  220  is separate or if the locking mechanism  220  is cylindrical and is nonfixedly incorporated to the container  210 , the locking mechanism  220  may be rotated prior to tightening, resulting in rotation of the ribbon  217 . 
   At the inner portion  240  of the substantially flexible member  215  is an inner flange  245 , which is a rigid region serving to secure the electrical work box  200  to the component  150 . The inner flange  245  may be solid ( FIG. 1A ) or hollowed out ( FIG. 1B ), integral with the substantially flexible member  215  or a separate component coupled to the substantially flexible member  215 . 
   A channel  250  formed by two formed segments ( 252  and  254 ) integrally molded into the electrical work box  200  positions the substantially flexible member  215  so that the inner flange  245  is properly orientated to secure the electrical work box  200  to the component  150 . There is a channel  250  on opposite corners of the electrical work box  200 . In certain applications, (including the mounting of ceiling fans or other heavy components), the channel  250  may be located on each of the four corners of the electrical work box  200  to accommodate four substantially flexible members  215 . 
   Prior to the installation of the electrical work box  200  into the opening  160  in the component  150 , outer region  242  of each substantially flexible member  215 , is inserted through its locking mechanism  220 . The length of the substantially flexible member  215  may be sufficient for the inner flange  245  to be bent behind a rear surface  235  of container  210 . After insertion of the electrical work box  200  so that the outer flanges  110  rest against the front surface  152  of component  150 , the inner end  242  of the substantially flexible member  215  and the inner flange  245  spring back so that the substantially flexible member  215  is substantially straight and the inner flange  245  is substantially perpendicular to an adjacent surface  232  of container  210 . Pulling of the outer region  242  of the substantially flexible member  215  through the locking mechanism  220  so that a latching surface  246  of inner flange  245  contacts the rear surface  154  of component  150  secures the electrical work box  200  to the component  150 . After securing of the electrical work box  200  to the component  150 , the outer region  242  of the substantially flexible member  215  beyond the locking mechanism  220  may be removed. 
   Installation of electrical work box  200  may also be accomplished by first inserting the outer region  242  of the substantially flexible member  215  through the locking mechanism  220  and pulling the substantially flexible member  215  through until the inner flange  245  overlaps a rear portion  234  of an adjacent surface  232  of the electrical work box  200 . The inner flange  245  is then rotated so that the inner flange  245  is substantially parallel to the adjacent surface  232 . Rotation may result in twisting of the substantially flexible member  215  or may be achieved by rotation of a cylindrical locking mechanism non fixedly incorporated or by rotation of the substantially flexible member  215  having cross sectional dimensions smaller than the size of the hole  225  where the locking mechanism  220  is separate. 
   The electrical work box  200  is then inserted through the opening  160  in component  150  until the outer flanges  225  of the electrical work box  200  rest against the front surface  152  of the component  150 . Initially, during the insertion, the orientation of the inner flange  225  where the substantially flexible member  225  is twisted is maintained by contact with a surface  162  of the opening  160 . As the inner flange  225  passes beyond the rear surface  154  of component  150 , the outer flange  225  twists until it is substantially perpendicular to the adjacent surface  232  of the container  210 . For a non fixedly incorporated or a separate locking mechanism  220 , rotation of the locking mechanism results in the outer flange  225  being perpendicular to the adjacent surface  232  of the container. Pulling of the outer end  242  of the substantially flexible member  215  through the locking mechanism  220  so that the latching surface  246  of the inner flange  245  contacts the rear surface  154  of component  150  secures the electrical work box  200  to the component  150 . After securing of the electrical work box  200  to the component  150 , the outer region  242  of the substantially flexible member  215  beyond the locking mechanism  220  may be removed. 
     FIG. 2  illustrates another embodiment of the invention where the inner portion  240  of the substantially flexible member  215  is coupled to the container  210  and the substantially flexible member  215  contains a rigid element  310  as a rigid region. The rigid element  310  may be integrally molded into the substantially flexible member  215 , as rigid molded segment  312  ( FIG. 2B ), or may be formed when a rigid channel  315  is coupled to the substantially flexible member  215 , as, for example, by crimping, or when the substantially flexible member  215  is threaded through the rigid channel  315  ( FIG. 2A ). 
   The length of the substantially flexible member  215  is sufficient that when the outer portion  242  is passed through the locking mechanism, a loop  520  is formed where the rigid element  310  lies beyond the rear surface  235  of the container  210 . As the electrical work box  200  is inserted through the opening  160  in the component  150 , the loop  520  is compressed to an extent that the combination of the compressed loops  410  and the container passes through the opening  160 . For a sufficiently thin rigid element  310 , the rigid region need not lie beyond the rear surface  235  of the container  210 , but may be held against a surface of the container  210  during insertion. ( FIG. 4E ). 
   When outer portion  242  of the substantially flexible member  215  is pulled through the locking mechanism  220 , a triangular buttress  320  is formed. When the substantially flexible member  215  can no longer be pulled through the locking mechanism  220 , a support portion  325  of the substantially flexible member  215  that is adjacent to the rigid element  310  is in contact with the rear surface  154  of component  150  and holds the electrical work box  200  against the component  150 . 
   Rather than as a separate item, the locking mechanism  220  may be incorporated into the container  210 .  FIG. 3A  illustrates an embodiment where the locking mechanism  220  is integrated into the container  210  by insertion and the inner portion  240  of the flexible member  215  is coupled to the locking mechanism  220 . In this case, a standard cable tie may be used and a rigid channel  315  crimped over a portion of the substantially flexible member  215  to form a rigid element  310 .  FIG. 3B  illustrates an embodiment where the locking mechanism  220  is integral with the container  210  and the inner portion  240  of the substantially flexible member  215  is coupled to the container. Also, the recess is a hole  410 . 
     FIGS. 4A ,  4 D, and  4 E illustrate a pre-deployment (above) and a post-deployment (below) state of the electrical work box  200 .  FIG. 4A  illustrates a side view of a solid inner flange  245  oriented parallel to electrical work box top  501  during insertion of the electrical work box  200  through opening  160  in component  150  and perpendicular to the electrical work box bottom  502  following reorientation by rotation through 90 degrees.  FIG. 4B  illustrates a top view of the electrical work box  200  showing the orientation of the inner flange  245  following insertion of the electrical work box  200  but prior to reorientation of the inner flange  245 .  FIG. 4C  illustrates a bottom view of the inner flange  245  following reorientation by rotation by rotation by 90 degrees so as to be oriented perpendicular to the bottom  502  of the electrical work box  200 .  FIG. 4D  illustrates insertion of electrical work box  200  and reorientation of hollow inner flange  245 . 
     FIG. 4E  illustrates a pre-deployment and a post-deployment state of the electrical work box  200  where rigid region  310  corresponds to the rigid channel  315  coupled to the substantially flexible member  215 . During pre-deployment, the substantially flexible member  215  forms a loop  520 . During deployment, the outer end  242  of substantially flexible member  215  is pulled away from component  150 , causing an outer end  530  of rigid channel  315  to be coupled to the component  150 , thereby preventing further pulling away of the substantially flexible member  215 . The loop  520  assumes a triangular shape  540  where the rigid channel  315  couples to the component  150  at the outer end  530  and to the electrical work box  200  at an inner end  535 . 
     FIG. 5  illustrates a process  600  of the present invention for mounting a device that includes a structure that may be the container  210  to a component  150 . In Step  610 , an opening  160  is created in the component  150 . In Step  620 , the substantially flexible member  215  is inserted through the opening  160 , through the opening  270  in a portion of the device such as the structure, and through locking mechanism  220 . In the case of the substantially flexible member  215  containing the rigid element  310 , insertion results in formation of the loop  520 . In step  630 , the container  210  is inserted into the opening  160  in the component  150 . In Step  640 , the substantially flexible member  215  is pulled through the locking mechanism  220  until a rigid region of the substantially flexible member  215  couples to a surface  154  of the component  150  and an outer portion  242  of the substantially flexible member  215  engages with the locking mechanism  220 . 
   In alternative embodiments, the rigid element  310 , or more than one rigid element  310 , may be located elsewhere on the substantially flexible member to form other buttress shapes or configurations.  FIG. 6  illustrates an embodiment where a substantially flexible member  715  contains four rigid regions  310 . 
   In further embodiments, a buttress may be formed without a rigid element  310 .  FIG. 7A  illustrates an embodiment where a substantially flexible member  815  is substantially uniform.  FIG. 7B  illustrates a circular buttress  820  produced by pulling the outer portion  242  of the substantially flexible member  815  through the locking mechanism  220 . 
   A substantially flexible member may contain regions of substantially reduced thickness such as notches which are susceptible to bending.  FIG. 8A  illustrates a triangular buttress  920  produced by pulling the outer portion  242  of a substantially flexible member  915  containing two spatially separated notches  920 , located on a side  940  of substantially flexible member  915  opposite a side  945  containing grooves  219 , through the locking mechanism  220 . Inclusion of different numbers and locations of the notches  920  results in buttresses of different shapes. 
   Although the invention has been described with respect to various embodiments, it should be realized that this invention is also capable of a wide variety of further and other embodiments within the spirit and the scope of the appended claims.