Abstract:
A mounting device is used to mount a structure, such as a light fixture, in a panel, such as a wall or a door. The mounting device includes two frame halves having identical inner surfaces with press-fit bushings so that the mounting operation can be carried out by merely pressing the two frame halves together. The outer surfaces remain smooth and unbroken since screw holes are not needed.

Description:
TECHNICAL FIELD  
       [0001]     The present invention relates generally to devices for mounting windows or other structures in panels or walls. In particular, the present invention is directed to a mounting device having unmarred outer faces.  
       BACKGROUND OF THE INVENTION  
       [0002]     There are many applications requiring that a window or other fixture be mounted within a panel, wall or door. The most common example is that of a window mounted in a panel door, such as a garage door, or any other normally solid door.  
         [0003]     Another example is the mounting of recording instruments, with glass-covered dials or displays, within apertures cut in solid panels. A further example is the use of decorative devices placed within apertures in panels, and backlit to further enhance the decorative qualities of the materials so displayed.  
         [0004]     In any of the aforementioned applications, the devices for holding the window or other structure within the aperture must be rugged and easy to use. In some instances, low cost is especially important while in other application; a pleasing or decorative appearance is essential. In still other applications, the mounting device must be impervious to atmospheric conditions, including moisture, sunlight and extremes in temperature. In all of these applications, ease of installation is of the highest importance since difficult installation processes will often result in a flawed final product, compromising one or both of the integrity and the appearance of the final product. Consequently, the complexity of the mounting device and the amount of time and skill necessary to achieve proper installation becomes the controlling factor in mounting frames of all types.  
         [0005]     For example, U.S. Pat. No. 2,645,827 to Koll, (incorporated herein by reference) a complex cutout is required in order to accommodate a plurality of tongues, which are used to hold a mounting frame to the surrounding panel. Consequently, the mounting of windows using this system is time-consuming and difficult. Further, if the precise pattern is not achieved and all the notches not properly aligned, there could be substantial difficulty in using the mounting frame of Koll. Because of the complexity of the cut-out pattern, mis-cuts become far more likely than with a simple aperture cut-out pattern. As a result, a mistake that could result in the construction of the panel is likely when using the Koll mounting device.  
         [0006]     When using the device of U.S. Pat. No. 5,369,922 to Hansen, a simple aperture cut-out pattern can be used, thereby avoiding the drawback of the Koll device. In the arrangement of Hansen, a frame member is integral with a first frame and attach to cover the core of the wall in which the window is mounted. The frame member includes a plurality of pairs of ribs. Each pair is connected by a strip to form an elongated opening therebetween. A second frame includes a connection device consisting of elongating tongues provided with toothing and arranged in a longitudinal direction along the frame. The use of the device requires clipping together the two frames from each side of the wall from which the window is to be mounted. The second frame and the side toothings on each tongue cooperate with the side toothings on a corresponding or complementary pair of ribs on the other frame in order to hold the two frames together. The strength of this arrangement is that it is highly tamper-resistant, if complicated.  
         [0007]     Complexity in mounting device has always been a drawback. Anything that has to be assembled on a construction site should be kept as simple as possible. Accordingly, multiple separate parts should be avoided since they can be easily lost. Likewise, additional construction steps should also be eliminated if at all possible since unskilled personnel might very well make mistakes in the assembly process, thereby ruining the mounting frame compromising the mounted fixture, and entailing additional expense.  
         [0008]     Many mounting devices are also used in decorative applications but must nonetheless be very secure. Conventionally, such devices are held together with screws in order to obtain the requisite mechanical strength. Unfortunately, the screws must be placed through the outer face (or decorative face) of at least one of the two frames. Sometimes, screw holes are necessary in the outer face of both frames. This leads to unsightly outer faces, even when the screw holes are filled. Also, filing the screw holes (after mounting) requires additional time and effort, and may still lead to an unsightly frame face. This is particularly problematical when dealing with the mounting of decorative devices since the overall presentation can be compromised by an unsightly mounting frame face.  
         [0009]      FIG. 1  depicts a conventional example of such an arrangement. The mounting device is comprised of two frames  1 ,  2 , and is used to hold a windowpane  100  within an aperture in a wall panel  200 . As is typical in conventional devices, the two frame halves  1 ,  2  are held together by a screw (not shown). The two frames,  1 ,  2  are not identical since frame  2  has a screw bushing  5 , and frame  1  has a screw hole  4 . This hole allows the screw to be inserted into the top of frame  1  to engage at least the screw hole  6  of frame  2 .  
         [0010]     This arrangement is further depicted in  FIGS. 2 and 3 .  FIG. 2  depicts the outer surface of frame  1 , in which screw holes  4  are clearly obvious, and are a part of the appearance of the frame regardless of any other measures that might be taken.  FIG. 3  depicts the inner surface of frame  2 , including bushings  5  and mounting hole  6 .  
         [0011]     A key drawback with the conventional art depicted in  FIGS. 1-3  is that this mounting arrangement requires two different types of frame  1 , 2 . For example frame  2  can have a smooth outer face while frame  1  requires screw holes  4  through its outer face. As a result a uniform outer appearance is impossible, and decisions must be made regarding the placement of the frame with screw holes in its outer face.  
         [0012]     The manufacture of two separate types of mounting frame leads to additional costs, both in manufacture and in the assembly process. For example, twice the manufacturing effort is required to make a second type of frame, including very expensive tooling arrangements. This is true whether the frame is made of wood, vinyl, rubber or plastic. The manufacturing and handling is also complicated by the need to sort each mounting device according to two different complementary frames to be packaged for transport.  
         [0013]     The installer in the field is faced with the problem of deciding where the “rough” (frame with screw holes in its outer face) outer face will be located. Very often this is a difficult decision for unskilled personnel, and is often made incorrectly. Further, the mounting is not secure until all of the screws are driven in, often a very awkward process leading to damage of both the wall panel and the structure being mounted.  
         [0014]     While screws are normally sent as part of the packaging of the overall mounting device, they&#39;re often lost or misused in the field, creating additional problems in the mounting process. Even if the mounting process is carried out efficiently, there is still the tedious process of filling the screw holes to protect the screws. Most manufacturers will have preformed fill pieces for this purpose. However, these often become lost resulting in increased problems in the mounting process and/or an unsightly finished product, even in the hands of skilled installers.  
         [0015]     Consequently, there is still a need to provide a mounting device for holding a structure, such as a window, within a wall panel, where the mounting device is sufficiently strong while being easy to use, and suitable for decorative purposes. Such a device should eliminate loose parts, if at all possible, and require a mounting procedure that is sufficiently simplified so that untrained personnel can carry it out successfully.  
       SUMMARY OF THE INVENTION  
       [0016]     Accordingly, it is the first object of the present invention to provide a mounting device that overcomes the drawbacks of the conventional art.  
         [0017]     It is another object of the present invention to provide a window-mounting device that is easy to use, and requires only a simple cut-out.  
         [0018]     It is an additional object of the present invention to provide a mounting device for a window, instrument, decorative device, or other fixture that can be installed efficiently and quickly.  
         [0019]     It is a further object of the present invention to provide a mounting device that can be quickly assembled by means of a simple press-fit engagement, requiring no tools for the assembly of the mounting device.  
         [0020]     It is still another object of the present invention to provide a mounting device having unmarred outer faces that can be used for decorative applications.  
         [0021]     It is again another object of the present invention to provide a mounting device that utilizes only a single type of frame.  
         [0022]     It is yet a further object of the present invention to provide a mounting device that is less expensive to manufacture than conventional devices.  
         [0023]     It is still an additional object of the present invention to provide a mounting device having a simplified assembly procedure.  
         [0024]     It is yet another object of the present invention to provide a mounting frame that eliminates loose parts that can be easily lost at a field assembly site.  
         [0025]     It again a further object of the present invention to provide a mounting device having outer surfaces which can be freely configured, and not constrained by the necessity of mounting holes.  
         [0026]     These and other goals and objects of the present invention are achieved by a mounting device arranged to mount a structure in a panel. The mounting device includes press-fit connectors for holding the two frames of the mounting device to each other.  
         [0027]     In another manifestation of the present invention a mounting device is arranged to mount a structure in a panel between two frames having identical inner faces. An arrangement of male and female press-fit bushings is included on the inner faces of the frames.  
         [0028]     A further manifestation of the present invention is found in a mounting device having two frames for mounting a structure in a panel. The opposite inner surfaces of both frames have connector bushings and both frames have continuous outer surfaces unbroken by mounting holes. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0029]      FIG. 1  is a cross sectional view of a mounting device holding a structure  100  in an aperture in a panel  200 .  
         [0030]      FIG. 2  is a top view of an outer face of a first type of conventional mounting frame  1 .  
         [0031]      FIG. 3  is a top view of an inner face of a second type of conventional mounting frame  2 .  
         [0032]      FIG. 4  is a schematic representation depicting the arrangement of connecting devices on two identical frames  10  of the present invention.  
         [0033]      FIG. 5  is a side view depicting the connecting devices of two identical frames  10  of the present invention.  
         [0034]      FIG. 6  is a top view of a spring clip  15  used as part of the present invention. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0035]     The present invention, as depicted in  FIGS. 4, 5  and  6 , provides a number of improvements over the conventional art, depicted in  FIGS. 1-3 . In particular, with the present invention there are no screw holes in the outer faces of frames  10 . This in contrast to those frames  1 ,  2  depicted in  FIGS. 1-3  of the conventional art. Rather, the outer surface of both frames  10  of the present invention can be identical, containing no screw holes or other such expedient to mar these smooth outer surfaces. Also of particular importance, the outer surface of the frames are no longer constrained in their shape or appearance by the necessity of screw holes. Accordingly, irregular, convoluted or fancy outer faces are now permitted where screw holes would have forced a shape or design inductive to the use of screw holes.  
         [0036]     The drawbacks of the conventional art is that two types of frame,  1  and  2  (as depicted in  FIGS. 2 and 3 , respectively) are required. This drastically increases the cost of making a mounting device over what it would be if only a single type of frame had to be manufactured. In contrast, the present invention utilizes the same frame  10  (as depicted in  FIG. 4 ) for both halves of the mounting device. The same frame can be used on either side, and be fitted with complementary connects simply by rotating the frame 180 degrees. Because the same frame  10  can be used on both sides, manufacturing cost are substantially reduced. Likewise, the expense of shipping and installation are also substantially reduced since even unskilled personnel can easily use the inventive mounting device with virtually flawless results.  
         [0037]     Further, while the outer surface (not shown) of conventional frame  2  (in  FIG. 2 ) is smooth and useful for decorative purposes, this is not the case for this outer surface of conventional frame  1  (as depicted in  FIG. 1 ). With the frame  10  of the present invention, there is no need for either screw holes or screw bushings. As a result, a great deal more latitude is permitted in the shape and thickness of the two frames  10 .  
         [0038]     No decision has to be made regarding the placement of the “unattractive side” of the mounting frame that is conventionally marred with screw holes. With the present invention, there are simply no screw holes, and no decisions to make regarding the placement of the “good” and “bad” sides of the frame.  
         [0039]     Other conventional drawbacks are also eliminated, including the improper use of wood screws or other self-tapping screws, and the unskillful placement of conventional plugs over screw heads once mounted. Since the present invention eliminates the necessity of screws, a great deal of time is saved in the overall assembly of the mounting frames of the present invention.  
         [0040]     The present invention uses only a single type of frame. The two frames  10  depicted in  FIG. 4  are identical. However, each has a different connector configuration on each of its two longitudinal legs. Details of the connector bushings  12 ,  13  are depicted in  FIG. 5  and  6 . The connections depicted in  FIG. 5  are characterized as press-fit connections.  
         [0041]      FIG. 5  depicts two identical frames  10  arranged to be connected to each other, thereby holding a device (not shown) within an aperture (not shown) in a panel (not shown), such as a wall. Each of the frames  10  is identical. However, the connector bushing arrangements on the two longitudinal legs,  10 ( a ),  10 ( b ) are different, and complementary to the other. The two types of connector bushings  12 ,  13  each extends from the inner surface of the frames  10 . The connector bushing of the two longitudinal legs,  10 ( a ),  10 ( b ), are arranged so that longitudinal leg  10 ( a ) of one frame can be press-fit to longitudinal leg  10 ( b ) of the other frame since these two are complementary to each other.  
         [0042]     The connector bushings  12 ,  13  are two types. Receiving bushing  13  is arranged in a female configuration to receive a projecting shaft. Projecting bushing  12  is arranged to include a shaft that will be received by receiving bushing  13 . Receiving bushing  13  includes a metal spring retainer  15 , also known as a spring clip, a J-nut, or a U-nut. This is a standard fitting, well known in the connector art, and illustrated in the  FIG. 6 . Spring clips such as  15  are preferably made out of metal, and include a central passage  151  with convoluted sides  152  to lock or otherwise hold an object passed through the spring clip.  
         [0043]     The sides  152  of spring clip  15  are pushed downward by a protrusion (such as shaft  14 ) inserted into opening  151 . Because spring clip  15  is made of a flexible material such as metal, plastic, rubber, or nylon, there is a strong tendency for the edges  152  to return to their normal position after being deformed by the presence of an object passing through opening  151 . However, if the object remains, a spring like action will tend to hold the object within opening  151 .  
         [0044]     In the present invention, shaft  14  on projecting bushing  12  is arranged opposite receiving bushing  13  which contains spring clip  15 . The holding action of spring clip  15  is further facilitated by annular ridges grooves  16  around shaft  14 . The grooves help hold the edges  152  of the spring clip  15 . The advantage of this arrangement is that the two frames  10  can be easily aligned with each other and pressed together to form a permanent connection holding the device  100  within an aperture of panel  200 .  
         [0045]     Spring clips  15  are generally held to receiving bushing  13  by means of an adhesive strip or bead  17 . Spring clip  15  can be recessed within body of bushing  13 , or can be mounted on the upper surface and held by a bead of adhesive, such as glue or caulking. The spring clip  15  can also be held by means of ultrasonic, chemical or heat welding on the appropriate part of bushing  13 .  
         [0046]      FIG. 4  depicts the projecting and receiver bushing arrangement that can be used with the present invention. Both frames  10  are shown with their inner faces pointing upwards to properly depict the arrangement of the projecting bushings  12  and the receiving bushings  13 . For the two frames to be placed together for mounting object  100 , the upper frame would be rotated into the Z axis (upwardly perpendicular from the plane of the paper), and onto the lower frame. In this manner, the connecting bushings  12 ,  13  of longitudinal leg  10  ( b ) of one frame  10  would be aligned with the connecting bushings,  12 ,  13  of longitudinal leg  10  ( a ) of the other frame  10 .  
         [0047]     It should be understood that  FIG. 4  depicts only one possible arrangement. There are many other configurations of connecting bushings  12 ,  13 , which could be used within the concept of the present invention. For example, a complementary configuration of connecting bushings can be placed on this latitudinal legs of the two frames  10 , in the same manner as is done with the longitudinal legs  10  ( a ),  10  ( b ). In this manner, only a single type of frame need be manufactured. The key is that one of the longitudinal legs be a complement with connecting bushing to the other longitudinal legs, while the same must hold true for any latitudinal legs that have connecting bushings. Further, any variety of complimentary arrangements can be used on the longitudinal legs ( 10   a ,  10   b ), or latitudinal legs as dictated by the specific use to which the mounting device is to be put.  
         [0048]     The particular configuration of the edges  152  of the spring clip  15  has been depicted in  FIG. 6 . However, other shapes and configurations for the spring clip can also be used. Likewise, the grooves  16  on shaft  14  can also be configured any manner which best suits the inner face with the edges  152  of spring clip  15 . For example, ratchet teeth, or a helical screw configuration can be used as the grooves  16  on stud  14 .  
         [0049]     While a number of examples of the present invention have to be presented by way of example, the present invention is not meant to be limited thereby. Rather, any and all variations, adaptation, modifications, derivations, and embodiments that would occur to one skilled in this art considered to be within concept of the present invention. Accordingly, the present invention should be construed as being limited only by the following claims.