Magnetic recoil fastener assembly for in-wall speaker installations

A magnetic recoil fastener assembly comprises a fastener with a head and a shank, and two annular magnets. When assembled, the annular magnets are arranged on the shank of the fastener to magnetically repel each other. At least the magnet arranged closer to the head of the fastener has a varying inner diameter of its axial opening, including a first diameter at one end which is larger than the width of the head, and a second diameter which is smaller than the width of the head. The end having the larger first diameter is arranged facing the head of the fastener. Also described are in-wall speaker assemblies including such magnetic recoil fastener assemblies for magnetically mounting speaker grilles in an adjustable manner, as well as methods for installing such in-wall speaker assemblies using such magnetic recoil fastener assemblies.

BACKGROUND

The background of the present disclosure relates to in-wall speaker installations. In-wall speaker installations allow for an audio system without occupying open room space, compared to freestanding speakers and on-wall mounted speakers. In-wall speakers can include woofer, midrange and/or tweeter speakers and can be installed in vertical walls, ceilings and/or floors. It is generally desirable that in-wall speakers provide a pleasing aesthetic with the surrounding wall surface. For example, an in-wall speaker's appearance may be minimalized to only its speaker grille for a clean look. In which case, it can be preferable that the position of the speaker grille is flush with the surrounding wall surface, that the means for mounting the grille are not visible from the room space, and that the grille is readily removeable for purposes of cleaning, replacement, painting, etc.

For these reasons, some in-wall speaker assemblies have used magnets to mount metal speaker grilles. In one approach, a ring-shaped speaker grille mounting component is spaced apart from a separate anchoring structure, which structure may be a part of a speaker housing or a woofer connector port depending on the type of speaker. The ring component is coupled to the anchoring structure by screws, with the free ends of the screw shanks being inserted into the anchoring structure and the screw heads being provided on a ring-shaped end surface of the ring component opposite the anchoring structure. The ring component is mechanically biased outward from the anchoring structure by springs positioned between the ring component and the anchoring structure. The end surface of the ring component opposite the anchoring structure and springs also carries magnets, to which the grille is magnetically coupled. The magnets are positioned along this ring-shaped surface along with the heads of the screws. The position and plane of the ring component, and thus the position and plane of the magnets for mounting the speaker grille, can be adjusted by tightening one or more screws inward against the spring force and/or by loosening one or more screws outward away from the anchoring component. While this approach allows for a magnetic and adjustable mounting of the speaker grille, it is also relatively complex requiring numerous components as well as mechanical spring mechanisms.

The foregoing examples of the related art and limitations therewith are intended to be illustrative and not exclusive. Other limitations of the related art will become apparent to those of skill in the art upon a reading of the specification and a study of the drawings.

SUMMARY

The following embodiments and aspects thereof are described and depicted in conjunction with systems, tool and methods which are meant to be illustrative, not limiting in scope. In various embodiments, one or more problems above have been reduced or eliminated, while other embodiments are directed to other improvements.

Proceeding from this background, the present disclosure proposes a magnetic recoil fastener assembly, and in particular a magnetic recoil fastener assembly for use with such in-wall speaker installations, though various other use applications are also available. Such a fastener assembly comprises a fastener and two magnets. The fastener has a head at one end and a shank extending from the head. The side of the head facing the free end of the shank forms a magnet contact surface for the first magnet. The first magnet is ring-shaped with a fastener insertion opening for receiving the fastener. The fastener insertion opening of the first magnet has a first inner diameter and a second inner diameter. The first inner diameter is larger than the diameter of the head of the fastener. The second inner diameter is smaller than the diameter of the fastener head, but larger than the diameter of the fastener shank. A fastener contact surface of the first magnet is thus provided between the first inner diameter and the second inner diameter within the fastener insertion opening. The second magnet is also ring-shaped with a fastener insertion opening for receiving the fastener. The fastener insertion opening of the second magnet is at least larger than the diameter of the shank of the fastener.

When assembled, the first and second magnets are arranged along the shank of the fastener to magnetically repel each other, with the first magnet being disposed closer to the head of the fastener than the second ring magnet. Therefore, the first magnet is magnetically biased along the shank in the direction of the head, such that the fastener contact surface of the first magnet contacts the magnet contact surface of the fastener head. The first magnet can be used to carry a mounted element made of a magnetic material, such as a speaker grille or an intermediary installation part for an in-wall speaker assembly. Multiple fastener assemblies can be used depending on the carrying requirements for the mounted element.

In use, the fastener will be anchored with respect to a substrate. By adjusting the depth of the fastener shank with respect to the substrate, the position of the first magnet in its biased position against the fastener head is also adjusted. In this way, the position and plane of a mounted element may also be adjusted. The first magnet, and a mounted element thereon, can be pushed against the magnetic force in the direction of second magnet. This movement may be used to break a drywall or paint seal, for example, where the mounted element is an intermediary component such as a sanding or painting shield used during an installation process.

For speaker applications in particular, it is preferable if the substrate comprises a magnetic material such that the second magnet will magnetically attach to the substrate, and/or the space between the first and second magnets when assembled is such that the second magnet is biased into secure contact with the substrate due to its magnetic force interaction with the first magnet. This can reduce or eliminate vibration of the second magnet on the fastener shank caused by audio output, which vibration could result in an undesirable rattling noise observed by the listener. Likewise, the magnetic repulsion between the first and second magnets can reduce or eliminate vibration of the first magnet on the fastener shank, since the first magnet is biased into contact with the fastener head.

In general, an adjustable magnetic mounting system may include at least one such magnetic recoil fastener assembly, and further comprise a surface which surrounds an opening formed in the surface, a substrate located within the opening and at a distance from the surface surrounding the opening, and a mounted element (e.g., a speaker grille or vent cover) shaped to cover the opening. When assembled, the at least one fastener assembly is arranged within the opening, with the shank of the at least one fastener assembly anchored with respect to the substrate, and the mounted element is magnetically attached to the first ring magnet of the at least one fastener assembly, such that a positional plane of the mounted element is adjustable by adjusting a depth of the fastener of the at least one fastener assembly relative to the substrate. A method for mounting the mounted element with this system may comprise: anchoring the shank of the at least one fastener assembly to the substrate within the opening; magnetically attaching the mounted element to the first magnet of the at least one fastener assembly within the opening; and if the positional plane of the mounted element is not flush with the surface surrounding the opening, then adjusting the depth of the fastener of the at least one fastener assembly relative to the substrate, such that the positional plane of the mounted element is flush with the surface surrounding the opening.

The preceding discussion is provided to introduce a selection of concepts in a simplified form that are further described below. The preceding discussion is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter. Other features, details, utilities, and advantages will be apparent from the below descriptions of various implementations as further illustrated in the accompanying drawings, wherein like reference characters designate corresponding parts in the several views.

Before explaining the depicted embodiments, it is to be understood that the invention is not limited in its application to the details of the particular arrangements shown, since the invention is capable of other embodiments. It is intended that the embodiments and figures disclosed herein are to be considered illustrative rather than limiting. Also, the terminology used herein is for the purposes of description and not limitation.

DETAILED DESCRIPTION

Certain terminology is used in the following description for the purposes of clear and concise explanation, which should not be considered or construed as limiting. For example, terms such as “connected” or “attached” include both directly and indirectly connected or attached, respectively, unless expressly indicated otherwise. This applies not only to these specific terms, but also to similar, related, and derivative terms and phrases as well.

Referring now toFIGS. 1-4, a fastener assembly100comprises a fastener110, a first magnet120, and a second magnet130. The assembly100is shown mounted onto a substrate10. The fastener110has a head112at one end and a shank114extending therefrom. The side of the head112facing in the direction of the shank114provides a magnet contact surface116, which interfaces with a fastener contact surface122of the first magnet120. The fastener110itself may be made from a magnetic or non-magnetic material.

The first magnet120and second magnet130are annular or ring-shaped magnets with a center aperture or insertion opening124through which the shank114of the fastener110is inserted when assembled. The magnets120,130are arranged on the fastener110in a manner to magnetically repel each other. The opposing orientation of the north and south poles of magnets120,130is shown by the “N” and “S” labeled arrows inFIGS. 1 and 2.

At least the first magnet120has a varying inner diameter dimension. As better seen inFIG. 9, a first inner diameter126of the fastener insertion opening124is larger than the diameter of the head112of the fastener110, such that the head112can pass through a portion of the magnet120with this dimension126. A second inner diameter128of the fastener insertion opening124is smaller than the diameter of the head112—such that the magnet120cannot be pulled off the fastener110in the direction of the head112—but larger than the diameter of the shank114such that the magnet120can be displaced along the shank114to the head112. The fastener contact surface122of the magnet120is provided within the fastener insertion opening124and extends between the first inner diameter126and the second inner diameter128.

Due to the opposing magnetic force between the magnets120,130described above, the first magnet120is biased against the head112inFIGS. 1 and 3. In this position, the fastener contact surface122of the magnet120abuts the magnet contact surface116of the head112. InFIGS. 2 and 4, the first magnet120has been moved along the shank114in a direction away from the head112against the magnetic force of the second magnet130. In this position, the fastener contact surface122is moved away from and no longer contacts the magnet contact surface116. In some applications, it is advantageous if the space between the first and second magnets120,130when assembled is selected to be small enough to securely bias the second magnet120against the substrate10via the magnetic field interaction between the first and second magnets120,130(the size of the space being variable depending on the strengths of the magnets used), and/or if the substrate10comprises a magnetic material such that the second magnet130is magnetically coupled to the substrate10.

FIGS. 4-8show another embodiment of the fastener assembly100. The previous discussion applies equally here except as otherwise indicated. In this embodiment, the extension of the first magnet120along the longitudinal axis of the fastener110, and the portion of the fastener insertion opening124of the first magnet120with the larger first inner diameter126, is greater than in the previous embodiment ofFIGS. 1-4(also compareFIG. 9withFIG. 11). Therefore, compared to the previous embodiment, the first magnet120can be moved from its position biased against the head112(seeFIGS. 5 and 7) against the opposing magnetic force provided by the second magnet130farther along the fastener110before the end of the magnet120coincides with the plane of the outer end of the head112(seeFIGS. 6 and 8).

Additionally, the second magnet130in the embodiment ofFIGS. 5-8is provided as a simple annular or ring-shaped magnet with a generally constant inner diameter. In the embodiment ofFIGS. 1-4, the first magnet120and the second magnet130share the same construction, meaning either magnet can be selected as the first magnet or second magnet during assembly. Either embodiment may use either approach, and both approaches can be advantageous depending on the circumstances. For example, it may be more cost effective to use ring magnets without a varying inner diameter construction for the second magnet130. Or it may be more cost effective to source and stock a single component for both magnets. It may also be beneficial to use the same magnet for the first and second magnets since the magnets are then readily interchangeable during assembly and use.

Details described above regarding the fastener contact surface122, fastener insertion opening124, first inner diameter126, second inner diameter128of the first magnet120are better visible inFIGS. 9 and 11for the embodiments ofFIGS. 1-4 and 5-8, respectively.

FIG. 10shows an alternative construction for the first magnet120ofFIG. 9. In this embodiment, the variable inner diameter of the fastener insertion opening124is provided as a counterbore, rather than as a countersink as shown inFIG. 9. Therefore, the fastener contact surface122extends radially from the longitudinal axis between the first inner diameter126and the second inner diameter128, rather than along the longitudinal axis at an angle as shown inFIG. 9. In this construction, the fastener head112may have a flat underside (not shown) rather than a tapered underside as shown inFIGS. 3 and 4, as is common in many types of fasteners, in order to accommodate the interface between the magnet contact surface116and the fastener contact surface122. Of course, the location of the fastener contact surface122, and therefore the depth of the first inner diameter126along the longitudinal axis, can be varied for a given application as desired.FIG. 12shows the same alternative construction for the first magnet120ofFIG. 11.

It should be appreciated that although the fastener110is shown as a screw with threading along its entire shank114mated into the substrate10, other fastener configurations may also be used for the assembly100. As described above, the underside of the head112—which faces the shank114and provides the magnet contact surface116—may be tapered, flat, rounded, etc. The opposite side of the head112, which faces away from the shank114, may likewise be flat, round, chamfered, etc. The torque drive for the head112may be cross, slot, hex, square, etc. Still further, the fastener110may be used with a nut in the manner of a bolt. The shank114may be unthreaded in portions, particularly since the head112of the fastener110in the assembly100is intended to be positioned away from the substrate10in order to accommodate the magnets120,130therebetween, such that threading can be omitted through this free area of the shank114. In sum, a wide variety of modifications to the depicted embodiments are possible.

Turning now toFIGS. 13 and 14, a mounted element140is schematically shown attached to the head portion of a fastener assembly100(the second magnet130is omitted here). The mounted element140is made of a magnetic material such that it responds to the magnetic field of the first magnet120and magnetically couples to the first magnet120. The position of the fastener110with respect to substrate10(not shown) has been adjusted such that the mounted element140is flush with the surface150surrounding the mounted element140inFIG. 13. InFIG. 14, the mounted element140and the first magnet120have been moved in the direction of the shank114—against the magnetic force of the second magnet130—until the mounted element140is stopped by the head112of the fastener110. Generally, the mounted element140will be much larger than shown, such as in the case of a speaker grille, sanding shield plate, or painting shield plate, and in which case, typically supported by multiple fastener assemblies100. In the case of a sanding shield plate where drywall has been mudded onto element140and surfaces150opposite the fastener assembly100, for example, the act of pushing the mounted element140out from the position ofFIG. 13into the position ofFIG. 14can be used to break the drywall seam between element140and surfaces150. Likewise, in the case of a painting shield plate where paint has been applied onto element140and surfaces150opposite the fastener assembly100, for example, the act of pushing the mounted element140out from the position ofFIG. 13into the position ofFIG. 14can be used to break the paint seam between element140and surfaces150.

Turning now toFIGS. 15-17, a speaker assembly200is shown for a ceiling-mounted drywall installation. An assembly mounting panel202will replace a portion of the regular ceiling drywall and be secured to one or more load-bearing structures (e.g. building framing). This may be a new build or retrofit installation. A bracket204is provided on the top side of the panel202for securing, via fasteners206, a speaker port210to the panel202in a clamping manner. As better seen inFIG. 18, the speaker port210is generally constructed as a hollow cylinder212with a perforated mud plate214extending radially outward from an end of the cylinder212. As described in more detail below, bosses216are provided along the interior surface of the cylinder212(only one boss216is visible in the view ofFIG. 18; the other boss217here is used to attach the midrange speaker208to the speaker port210). The speaker port210has a mud dam218which projects outward from the perforated mud plate214around the opening of the hollow cylinder212. The mud dam218is the portion of the speaker port210visible on the bottom side of the panel202inFIG. 15; the mud plate214is otherwise positioned in a recess formed in the bottom side of the panel202and therefore not visible in the side profile view ofFIG. 15. Of course, it should be appreciated that the foregoing structures of the speaker port210may instead be designed and provided by separate components, rather than a single integral component as shown.

In the depicted assembly200, a midrange speaker208is provided at the end of the speaker port cylinder212opposite the perforated mud plate214. A tweeter speaker220is provided within the speaker port cylinder212and coupled to speaker port bosses216via fasteners222. The tweeter speaker220is smaller than the inner diameter of the port cylinder212to allow passage of audio output from the midrange speaker208through the port cylinder212. Therefore, this speaker assembly200has good audio range in that the audio output can crossover between the tweeter speaker220at higher frequencies to the midrange speaker208at lower frequencies, or can be simultaneously output from both speakers. Of course, other embodiments could have just the midrange speaker208or just the tweeter speaker220. In further embodiments (not shown), the audio speaker of the speaker assembly200is a woofer attached to the end of the port cylinder212opposite the mud plate214via a port tube.

After installation, a speaker grille224will cover the end of the speaker port cylinder212on the side having the mud plate214and mud dam218. The speaker grille224is made of a magnetic metal or other material, and magnetically coupled to the first magnets120of the fastener assemblies100. In the depicted speaker assembly200ofFIGS. 15-17, the fastener assemblies100are anchored in the housing of the tweeter speaker220(which therefore provides substrate10of the previous figures).

In speaker assemblies200without a tweeter speaker220mounted in the port cylinder212, such as assemblies with a woofer or the midrange speaker208only, the bosses216within the cylinder212may be used to anchor the fastener assemblies100directly. Alternatively, as shown inFIGS. 19 and 20, the cylinder bosses216may be used to mount a separate platform component226which then provides the substrate structure for the fastener assemblies100. The platform component226is designed to extend around the periphery of the interior surface of the cylinder212to leave the cylinder interior mostly open for passage of audio output from the midrange speaker208or woofer. For example, the platform component226may have a ring or C shape. The platform component226provides anchoring points around the periphery of the cylinder212for receiving fastener assemblies100. In the embodiment ofFIGS. 19 and 20, the platform component226has a C shape with three bosses228into which three fastener assemblies100are inserted. The fasteners222—which previously coupled the tweeter speaker220to bosses216in the arrangement ofFIG. 17—couple the platform component226to the cylinder bosses216. The platform component226may be readily produced by injection molding, for example, or any other suitable production method.

It should be appreciated that the number, positioning, and spacing of the fastener assemblies100may be readily selected and modified in view of the particular carrying requirements for a given application. For example, large or heavy speaker grilles224(or sanding/paint shield plates) may require additional fastener assemblies100, or at least strong first magnets120, to ensure such mounted elements140are sufficiently secure. Thus, the tweeter speaker220or the platform component226may be designed to carry more, or less, fastener assemblies100than depicted, in view of the carrying requirements for the mounted element140. Therefore, the separate platform component226allows the same speaker port210to be used, without modification, regardless of the speaker or fastener assembly configuration.

Note that the speaker assembly200is shown here prior to drywall mudding, sanding and painting as now described. During installation, the speaker grille224can be replaced by sanding and painting shields, which are removably coupled to together.FIGS. 21 and 22show one possible configuration for such installation shields. This shield assembly230comprises a sanding shield plate232and a painting shield plate234. The plates232,234are coupled together by a fastener236through the center thereof. The sanding shield plate232has an opening238and the painting shield plate234has a stamped tab240aligned over the sanding shield opening238. At least the painting shield plate234is made of a magnetic metal or other material in order to magnetically couple to the first magnets120of the fastener assemblies100. The sanding shield plate232and the painting shield plate234generally have the same shape as the speaker grille224, since these components stand in for the speaker grille224during installation and help ensure a clean final aesthetic. Once the panel202has been structurally mounted, the magnetic screw assemblies100are adjusted to set the sanding shield plate232coplanar with the end of the mud dam218of the speaker port210.

In a mudding step, the ceiling surrounding the panel202, the panel202, the perforated mud plate214, and at least the edges of the sanding shield plate232are mudded with a drywall compound, generally in multiple layers. Once dry, the mudded drywall is then sanded down to the mud dam218to produce a smooth ceiling surface. The sanding shield plate232, and therefore also the painting shield plate234, is then pushed upward along the fastener assemblies100to break the drywall seam, as described in reference toFIGS. 13 and 14, and the sanding shield plate232is removed from the painting shield plate234. For the depicted shield assembly230, the installation shield plates232,234are separated by first removing the plate fastener236. If the sanding shield plate232remains in place at that point, a tool (e.g. a screwdriver) may be inserted through the sanding shield opening238to act against the paint shield tab240and separate the plates232,234from one another.

In a painting step, the sanded ceiling surface is painted through at least the edges of the painting shield plate234. The painting shield plate234is then pushed upward along the fastener assemblies100to break the paint seam, as described in reference toFIGS. 13 and 14, and the painting shield plate234is removed. Again, a tool inserted into the opening of the paint shield tab240may be used, if necessary, to pull the paint shield234off the fastener assemblies100.

At this point, the speaker grille224may be mounted to the fastener assemblies100in the case of woofer or midrange speaker208only speaker assemblies200, or in the case of the depicted assembly200if the installation process was performed with the tweeter speaker220already in place. However, it is typically preferable to mud, sand and paint without the tweeter speaker220being mounted in the port cylinder212. This protects the tweeter speaker220from particle ingress during installation, and further, ensures there is adequate room within the cylinder212to complete the installation steps depending on the component design dimensions. For example, if the tweeter speaker220is positioned close to the end of the cylinder212, it could impede or otherwise interfere with setting the sanding/painting shield plates232,234in the correct position or moving them to sufficiently break the seams. Such considerations also apply where the sanding/paint shield plates are coupled together by a fastener which extends, at least by some amount, longitudinally into the port cylinder212past the painting shield, as is the case with the shield fastener236in the depicted shield assembly230. If the tweeter speaker220is not mounted within the speaker port210during the installation process, the platform component226may be used to anchor the fastener assemblies100for magnetic coupling with the shield assembly230. In which case, after painting, the platform component226is removed from the port cylinder212to allow the tweeter speaker220to then be mounted therein as described above.

In any event, the position of the speaker grille224is readily adjusted by varying the depth of the fastener110of the one or more fastener assemblies100. This adjustment can be used to ensure the speaker grille224is flush with the surrounding ceiling surface as desired.

Once fully installed and positionally set, the first magnets120of the fastener assemblies100carrying the speaker grille224are in the positions shown inFIGS. 1, 3, 5, 7and13. It should be noted that the first magnet120is already naturally biased downward against the fastener head112by gravity for horizontal ceiling-mounted speaker assemblies200, meaning the second magnet130is not strictly necessary to bias the first magnet120against the fastener head112by default. However, the audio output from the speaker assembly200has the potential to vibrate the first magnet120and/or grille224on the fastener110, which can cause undesirable rattling sounds during use and thereby decrease the sound quality. The repelling magnetic force of the second magnet130further biases the first magnet120outward against the head contact surface122and therefore helps to reduce or eliminate such vibration. Likewise, the second magnet130is preferably magnetically coupled to substrate10to reduce the potential for the second magnet130to vibrate against the fastener110due to audio output, and/or the space between the first and second magnets120,130along the shank114is preferably selected to be small enough such that the second magnet130is securely biased against the substrate10by the repelling magnetic force of the first magnet120. Such considerations also apply for speaker assemblies200installed in vertical walls. Depending on the embodiment, the substrate10for the fastener assemblies100may be provided by a component of the tweeter speaker housing220as in the depicted speaker assembly200, or the speaker port cylinder bosses216directly, or a separate platform component226mounted within the speaker port210as described above, or any other suitable anchoring structure.

Although the previous description is in the context of an in-ceiling speaker assembly with a smooth drywall finish, it should be appreciated that the systems and benefits described herein may be realized with various other finishes, such as wood, tile, etc., by routine modification to the installation process and components as needed. The disclosed magnetic recoil fastener assemblies may be used to adjust and set a speaker grille and any intermediary installation shields for an in-wall speaker assembly, as desired, regardless of wall finish.

Further, magnetic recoil fastener assemblies, systems and methods described herein may be used in any other contexts where it is desirable to mount a mounted element relative to a surface in an adjustable manner, and not just those related to speaker installations. For example, the fastener assemblies may be used to mount a vent cover in a duct opening, such that the vent cover sits flush with the wall surface surrounding the duct opening. The same applies for other in-wall devices other than speakers, such as sensors or cameras, in which case the design of the mounted covering is readily adaptable to accommodate the functionality thereof while allowing for a magnetic attachment to one or more first magnets of the fastener assemblies (e.g. a magnetic peripheral frame with a visually transparent center in the case of a camera). The surrounding surface—relative to which the mounted cover is adjusted—may be provided by non-wall objects as well, such as tables, counters or cabinetry for example. A wide variety of applications and uses are possible.

While a number of aspects and embodiments have been discussed above, those of skill in the art will recognize certain modifications, permutations, additions and sub-combinations therefor. It is therefore intended that the following appended claims hereinafter introduced are interpreted to include all such modifications, permutations, additions and sub-combinations, which are within their true spirit and scope. Each embodiment described herein has numerous equivalents.

The terms and expressions which have been employed are used as terms of description and not of limitation, and there is no intention in the use of such terms and expressions of excluding any equivalents of the features shown and described or portions thereof, but it is recognized that various modifications are possible within the scope of the invention claimed. Thus, it should be understood that although the present invention has been specifically disclosed by preferred embodiments and optional features, modification and variation of the concepts herein disclosed may be resorted to by those skilled in the art, and that such modifications and variations are considered to be within the scope of this invention as defined by the appended claims. Whenever a range is given in the specification, all intermediate ranges and subranges, as well as all individual values included in the ranges given are intended to be included in the disclosure. When a Markush group or other grouping is used herein, all individual members of the group and all combinations and sub-combinations possible of the group are intended to be individually included in the disclosure.