Devices and methods for flangeless installations

A flangeless mounting system, suitable for in-wall speakers and other components, includes a panel that is finished to provide at least a superficially continuous junction between the edges of the panel and the surrounding wall, ceiling, or other structure. A rim advantageously extends outwardly from a first surface of the panel by a small distance, which in currently preferred embodiments is about 1/16th inch to ⅛th inch. A collar is preferably installed about the inner edge of the opening, and a receiver is attached to the collar or directly to the panel. Magnetic, threaded, detent, and frictional means are contemplated for maintaining the component in position relative to the receiver.

FIELD OF THE INVENTION

The field of the invention is wall and ceiling receptacles.

BACKGROUND

Plasma screens, speakers, light switches, electrical outlets, junction boxes and other components are conventionally mounted by cutting a hole in a wall or ceiling, inserting a bracket, and then seating component being installed to the bracket. Since the cutout is performed at the job site, these conventional installations invariably produce a gap between wall or ceiling and the component being installed. That gap is usually covered with a flange, which can be relatively small, as in the case of flanges used around the edges of the electrical boxes for ceiling lights, speakers, or relatively large, as in the case of face plates for electrical outlets, light switches or other in-wall controls.

It is also known to install wall and ceiling component using flangeless installations. In prior artFIGS. 1A and 1B, for example, a panel10is placed behind the wallboard30. The speaker housing16extends out the back side of the panel10(i.e. inside the wall or ceiling), and a bracket14coupled to the panel10has a rim portion14A that extends above (on the front side of the wall or ceiling) the panel10by a distance15. The drywaller then cuts a hole in wallboard30up to the edge of the rim14. Additional examples are discussed in U.S. Pat. No. 7,032,708 to Popken et al. (April 2006), and U.S. Pat. No. 7,296,280 to Richie (October 1981). These and all other extrinsic materials identified herein are incorporated by reference in their entirety. Where a definition or use of a term in an incorporated reference is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein applies and the definition of that term in the reference does not apply.

In the known flangeless installations, a bracket is placed within the opening, a component is seated to the bracket, and the wall or ceiling is finished (typically by plastering) up to the edge of the bracket. Frames are sometimes used in place of a bracket to seat the component, and such cases the wall or ceiling is finished to the edge of the frame rather than to the edge of the bracket. This strategy is often used in hanging windows and doors, and has been adapted to installing speakers by U.S. 2007/0051862 to Monti (March 2007). In other known flangeless installations, as shown by U.S. 2004/0218777 to Hagman (November 2004), a frame is placed within the opening, a component is seated to a panel (i.e. inside the wall) that couples the frame, and an active member without an opening couples the frame forming an acoustic chamber inside the wall, and the wall or ceiling is finished (typically by plastering) up to a perimeter region of the active member.

The grandparent of the present application Ser. No. 11/548,381 filed Oct. 11, 2006, introduced the idea of installing the mounting bracket into a panel rather than the ceiling or wall. The panel can be significantly, at least two or three times, larger than the size of the opening that receives the component, and in such cases the finishing takes place away from the opening, where the installer has a much easier time producing a superficially continuous junction.

In the '381 application, however, it was still contemplated that the bracket would have a rim that extends above the plane of the panel. That still requires the installer to apply a very thin layer of plaster or other finishing compound up to the rim. What is still needed are methods and apparatus that can achieve a flush-mount appearance in walls, ceilings, and other structures, in which little or even no finishing is required around the periphery of the opening.

SUMMARY OF THE INVENTION

The present invention provides apparatus and methods in which a component is flush-mounted to a wall, ceiling or other substantially flat structure of a building using a panel and receiver assembly.

Preferred panels have compositions and thicknesses that match the structures to which they are being finished. For example, a half-inch thick plasterboard panel would advantageously be installed adjacent a half-inch thick plasterboard wall. Preferred panels have a front facing area of at least twice that of the opening into which the receiver is inserted, and/or extend at least three inches in at least one direction from the face of the receiver. More preferably the front facing area extends at least 5″, 7″ or 10″ in at least one direction from the face of the receiver.

Receivers can range from a simple rim disposed on the inside of the opening, to an extensive bracket and housing extending out the back of the panel. In any event, preferred assemblies have little or no discernable gap between the panel and the receiver. This can be accomplished in any suitable manner, including for example, accurately cutting the opening into which the receiver is installed, and then gluing the receiver to the panel. Where the panel comprises a formed substance such as drywall, another option is to form the panel around the receiver.

The panel can be finished to the structure in any suitable manner, including conventional taping and plastering. Because the panel is large relative to the opening, the finishing takes place away from the component, where finishing is easier to accomplish, and where small defects in the seam would tend not to be attributed to installation of the component. Panels are preferably coupled to an inner, rather than an outer, edge of the structure.

All types of components are contemplated for installation, but especially including components having electrical parts. For example, speakers, lights, switches, wall plugs, wall controls (audio, video, fan), thermostats, fire sprinklers, fire alarms and smoke alarms, mirrors, kitchen appliances, intercoms, air vents, vacuum outlets, security panels, and iPod docks and ports are all contemplated components

The component is preferably seated to the assembly in a removable manner, using a detent or biasing mechanism. Special removal tools are contemplated for releasing and withdrawing the component.

DETAILED DESCRIPTION

InFIG. 2a speaker mounting apparatus100generally includes a panel110with an opening120, and a bracket140disposed in the opening120, and attachment wings170A-170D. It should be appreciated that a speaker is used in these figures as an example of a wall mounted component. The same or analogous principles disclosed herein apply to plasma screens, in wall art panels, in wall cabinets or display areas, windows, and so forth.

Panel110is a piece of wallboard, wood, plastic, or other material sufficiently strong to support a speaker between two studs of a wall. Where plywood is used, for example, the panel might be as thin as ¼″, but would more preferably measure at least ½″ or ⅜″. Preferred materials include wallboard, Medium Density Fiberboard (MDF), High Density Fiberboard (MDF), Acrylonitrile Butadiene Styrene (ABS), and other materials that closely match various characteristics of drywall. Panel110can have any other suitable dimensions, even for example, up to the size of replacing an entire sheet of wallboard. It is preferable for the panel110, or at least the lateral wings170A,170C, to have a width at least six or twelve inches greater than the spacing between studs. The extra width allows the installer considerably greater flexibility in positioning the panel on the wall.

As used herein the term “wall” should be construed broadly to mean any sort of mechanical barrier to which a speaker or similar sized and weighted component could be attached. Thus, the term “wall” includes walls of buildings, machine housings, automobiles, cabinets and so forth, as well as doors and ceilings. Along the same lines, the term “wall section” should be interpreted as any modular portion of the wall. In standard home construction, for example, a wall section would likely be a 4′×8′ piece of wallboard.

The opening120can also be any suitable shape and size. Preferred openings are rectangular to accommodate rectangular shaped speaker housings, but could also be oval and circular or any other desired shape. The area of the opening is generally dependent on the size of the speaker, and can range up to 80 in2, or larger. Especially preferred openings have an area of at least 20 in2, 40 in2, 60 in2, and even 80 in2. Nevertheless, for stability, it is contemplated that the panel have an opening with a length that is no more than half or one third the length of the panel. In some cases it may be desirable to include multiple openings to accommodate multiple speakers, as inFIG. 7. Preferred embodiments with multiple openings provides at least two openings and at least one of which has an area of at least 20 in2.

Any opening can be positioned in any suitable arrangement relative to the panel110, and indeedFIG. 2shows an embodiment where the opening120is laterally off center with respect to the opening. Openings could be cut at a job site or elsewhere by an installer, but are more conveniently precut (or molded to include the opening) at the manufacturer. It is possible for a panel to have punch out openings or perhaps cutout lines to facilitate selection of the position of the opening at the job site, but those options are currently disfavored relative to a manufactured opening and a relatively large panel.

The top, bottom, and side wings170A-170D, respectively, preferably extend from the corresponding edges of the panel110by at least about one inch, which is deemed to be sufficient space to conveniently drive a nail or screw into a stud. It is also contemplated, however, that at least one of the wings170A-170D can extend much longer, perhaps 24 to 30 inches or more. Such long wings can accommodate odd installations where the studs are spread apart at a greater distance from each other than normal. Wings170A-170D are preferably made of a metal mesh, but can include of any suitable material or materials so long as the material(s) provide(s) sufficient shear strength to support the panel110and speaker16. Metal mesh is also desirable because the wings are advantageously relatively thin, so as not to push out the overlying wallboard, and metals can provide considerable strength with thickness of less than 100 mils. It should also be appreciated that although wings170A-170D are described herein by separate numerals, they may well be one continuous piece of material.

Bracket140is preferably sized and dimensioned to fit snugly into the opening120, but in any event is screwed or otherwise securely attached to the panel110. The secure attachment is important since in at least some embodiments, the speaker housing will be attached to the bracket140rather than being attached directly to the panel110. Bracket140is preferably molded from polyethylene or other sufficiently strong and durable thermoset plastic, and as shown in greater detail inFIG. 3bracket140includes holes142for screws (not shown), a recess144into which a speaker grille18can be removably secured via a holding mechanism, and a rim140A, and optional magnets146or an optional press fit (not shown).

FIG. 4also shows a speaker16A and a grille18. Speaker16A should be interpreted as generically representing all practical speakers, including especially dynamic loudspeakers, but also including speakers without moving coils (e.g. piezoelectric speakers, plasma arc loud-speakers, digital speakers, and electrostatic loudspeakers (ESL)). The various wires for power and signal are not show in the Figures, but should be assumed, and can be those conventionally contemplated in the art. Grille18can be any suitable speaker grille, but is preferably a metallic mesh grille that press-fits into the opening120. Additionally or alternatively, the bracket can include a ferrous material that is attracted to magnets146in bracket140.

It should also be appreciated that the same technology can also be used to support items other than speakers, including for example lights, switches, electrical outlets, windows, planters, alcoves and so forth.

As seen inFIG. 5the rim140A is sized and dimensioned to extend outwardly from the panel110by a very small distance150, which provides a lip that can readily be used as a stop against which to spread spackle or “mud”. Preferred such distances150are less than ⅛ inch, and preferably about 1/16 inch, or in metric terms about 1-2 mm. The height150of rim140A above the panel10is thus very different from the height15of rim14A above the panel10inFIG. 1B. In the prior art configuration the rim14A extends by more than the combined thickness of the panel10and the wallboard30. Preferably, the panel has a thickness of at least ¼ inch. Also shown inFIG. 5is an attachment member148that helps secure bracket140to panel110.

It should be appreciated that the rim could be separable from the panel. Thus, for example, the rim could be a separately molded piece of plastic, metal or composite that is installed into the opening by the installer, or at a factory.

InFIG. 6Athe panel110is affixed to two studs210A,210B in a wall, and screws215are inserted through one of the wings170A and the panel110. Of course, the positioning and orientation of the panel could be varied in any suitable manner with respect to the studs,210A,210B, including moving the panel110higher or lower, left or right, or even tilting the panel clockwise or counterclockwise. Similarly, the studs should be interpreted herein as emblematic of any support structures of a wall, whether or not such structures are technically considered to be studs. In addition, a greater or lesser number of screws could be used, or inserted in some other arrangement than that shown to provide greater or lesser support. The screws could also be replaced or supplemented by some other attachment means such as adhesive. In preparation for spackling, a spackle shield190covers the opening120.

Those skilled in the art will appreciate that the combination of panel and bracket could be provided in several different ways. The panel and bracket could, for example, be joined together at a job site, and indeed the panel could even be “manufactured” at the job site by cutting or punching out the opening. More preferably, however, the panel and bracket are provided as an item of manufacture to the installer by a supplier or manufacturer. The rim of the panel can be pre-installed to the panel. Thus, in various embodiments a kit could contain one or more of a panel, a bracket (or at least a rim around the edges of an opening in the panel), a speaker housing, a spackle shield, and installation screws. The installer would then provide whatever labor is appropriate for the installation, including optionally installing the bracket and/or rim, optionally installing the spackle shield, and optionally mounting the speaker into the speaker housing to the back side of the panel. It is also contemplated that the speaker can be pre-installed into the panel before installation. Alternatively the combination of the panel and bracket can be mounted before installing a rim on the opening.

InFIG. 6Bdrywall220or other wallboard has been installed on all four sides around the panel110, and coupled to the wings using screws215. Where wings are present, as in the embodiment depicted, the drywall220overlays the wings, but the wings are sufficiently thin so that the drywall is not noticeable raised. Those skilled in the art will appreciate that althoughFIG. 6Bshows the drywall220surrounding the panel110as a single piece, it is entirely possible that the drywall could comprise multiple pieces (not shown). It is also contemplated that installation of the drywall220might be delegated to drywaller or other tradesman distinct from the panel installer. Nevertheless, the process of installing the panel on one or more wall supports is deemed to include the step of positioning the panel so that it can be approximated in an end-to-end fashion by a piece of wallboard or other wall section.

InFIG. 6Cmesh tape230is applied along the juxtapositions or other approximations between edges of the panel110and edges of the drywall220. Here again, this step is usually delegated to a professional drywaller, but should be interpreted as being accomplished by the installer of the panel, regardless of which person actually does the work.

InFIG. 6Dthe mesh tape is covered by spackle, and ready for painting, wallpapering, or other surface coating. As used herein, the terms “spackle” and “spackling” should be interpreted as broadly as possible, to include for example plaster and plastering of any type. The point is merely to provide a smoothed out surface that completely or substantially hides the joints between edges of the panel and edges of the drywall.

InFIG. 7a panel300has two speaker openings320A and320B. These openings are each preferably at least 40 inch2in area, but can be any sizes or shapes, and can have any physically orientation and positioning with respect to each other. The openings320A,320B have brackets340A,340B, respectively, the panel300has wings370A-370D, all in accordance with the teaching herein.

InFIG. 8Aan installation800generally includes building structures810,820, an opening814on structure810, and a panel assembly830that will installed into the space814, as shown by arrow840.

As used herein, the term “assembly” means an object that has multiple components or functional portions. Thus, the term comprises: (a) multiple pieces that are coupled together in some manner, either temporarily or permanently; and also (b) a single molded object with multiple functional components. By way of example, panel assembly892inFIG. 11is a panel assembly molded as a single piece.

In typical installations, the structures810,820would be adjacent vertical walls, or a vertical wall and a ceiling, andFIG. 8Ashould be interpreted to include all such embodiments. Thus, for example, where structures810,820are interpreted to be vertical walls, members812,822should be interpreted as studs. Where structure810is interpreted as a ceiling, members812should be interpreted as joists, and members822should be interpreted as horizontal struts. Although the portions of the structures810.820depicted in the figure as substantially flat, those skilled in the art will appreciate that the structures could be curved, or have curved portions. In addition, those skilled in the art will appreciate that structure810could exist independently of structure820.

Structures810,820would typically comprise drywall, which term is used herein generically to include all manner of wallboard, fiberboard, gypsum board, GWB, plasterboard, SHEETROCK® and Gyproc®, and so forth. Additionally or alternatively, structures810,820could comprise other materials, including for example polymers, masonry, ceramics, and acoustic ceiling tile materials or other composites.

Structures810,820can have any suitable dimensions, from only a few square feet or less, to hundreds of square feet or more. Structures810,820will usually, however, have relatively small thicknesses of between ¼″ and 1″ in thickness.

Panel assembly830can be produced at a job site, for example, by cutting a hole out of a piece of drywall. The piece being used in such instances can be cut out from an existing vertical wall or ceiling, and or can be completely new to the job site. Either of those methods could work adequately for drywall, acoustic ceiling tile and other materials that are fairly easy to cut, but for difficult to cut materials, including for example polymers, masonry, and ceramics, the panel assembly can be most conveniently produced in a factory where the panel is dried or cured around a form (seeFIG. 11) to define the opening.

As discussed above with respect toFIGS. 2-7, the opening834ofFIG. 8Acan be any suitable size, shape, or number. As currently contemplated, it is desirable that the total front facing area consumed by the opening or openings be relatively small with respect to that of the panel832. That ratio is preferably at least 3, more preferably at least five. Viewed from another perspective, it is preferred that the panel832extend in at least one direction at least 3 inches from the closest edge of the opening834for light or other simple switches, electrical outlets and so forth, and at least 5 inches for lights, more complicated switches and other controllers, speakers and so forth. Where the component has a front-facing surface area of at least 25 in2, the panel832extend in at least one direction at least 12, 18, or even 24 inches from the closest edge of the opening834.

InFIG. 8Bthe panel assembly830has been placed within the space814. There will almost always be some gap between the edges of the panel assembly830and those of the surrounding structural component810, ranging in typical installations from zero (where the panel assembly830is abutted against the structural component810), and perhaps ⅛″ to ¼″. Indeed, there will almost always be multiple different gaps around the edge of the panel assembly. Where the workmanship is sloppy, or the project is especially difficult, the gap in some sections can be larger. In addition, it is contemplated that an intermediate member (not shown), as for example a paper, shim, or even a frame can be installed in the gap between the panel assembly830and the structural component810. As long as the edges of the assembly and the structure are somewhat near each other, and the gap can be finished such that an at least superficially continuous junction is established between them, the edges are considered to be approximated.

InFIG. 8Cthe approximated edges of the panel assembly and the structure have been finished to provide an at least superficially continuous junction. As used herein the term “at least superficially continuous junction” refers to a junction that appears to casual observation to be seamless. By way of example, a good workman-like job in taping and plastering adjacent sections of wall board is considered herein to produce an at least superficially continuous junction, especially where subsequent painting or wallpapering eliminates any seam apparent to casual observation.

InFIG. 9a rear view of the panel assembly830ofFIGS. 8A-8Cshows a receiver838and attachments836of the receiver to the panel832. The receiver838in this instance is an open box, but all manner of alternative receivers are also contemplated. For example, receivers could be tubular or have some other shape, and could be completely or partially closed, and can have punch outs such as those found on a typical electrical connection box.

The attachments836are shown as four wings, extending from the four sides of the receiver838, and then glued, nailed, stapled or otherwise affixed to the panel832. Those skilled in the art will appreciate that still other methods could be used, including forming the panel832around the wings. Still further, it is contemplated that wings could be eliminated altogether. In a ¾″ or 1″ thick fiberboard, for example, a collar pressed into the opening, or used as a form around which the fiberboard is made, might have sufficient strength to hold a relatively lightweight component.

FIGS. 10A-10Ddepict alternative mechanisms for seating various components861-864within receivers838. InFIG. 10Athe mechanism comprises magnets872. InFIG. 10B, the mechanism comprises a long threaded bolt874A that is turned into a nut874B. InFIG. 10Cthe mechanism comprises detents that fit within biasing members876B. InFIG. 10Dthe mechanism comprises a compressible polymer or fabric that fits in the gap between the rear portion864B of the component864, and the receiver838. In this particular example, the facing plate864A of the component864is larger across than the rear portion864B.

In the Figures component861is a speaker or other speaker assembly861A, component862is a light or other switch, (showing toggle862A), component863is a light, light fixture or other light assembly, and component864is a generic component that should euphemistically be viewed as an electrical outlet, or any other reasonably installable component. Of course, the combinations expressly depicted in the Figures are merely examples, and thus it should be appreciated that one could combine any of the components861-864with any of the depicted seating mechanisms, or indeed any suitable seating mechanism.

FIGS. 10A-10Dalso demonstrate that the face of the components are only optionally made completely flush with the face of the panel832when they seat with the receiver838.FIG. 10D, for example, shows a face portion864A that is recessed from the face of the panel832. Here, those skilled in the art will appreciate that the recess is exaggerated to assist visualization. In practice, any such recess or extension would likely be less than ⅛thinch. Furthermore, it is contemplated that the components can be easily removed by extraction tools, such as a screwdriver and the like, to provide for simpler change of installation.

FIG. 11is a perspective view of a panel assembly892being formed by pouring a panel material from container832into a mold894. This process brings the poured material right up against the frame portion that defines the opening896, regardless of any irregularity or other difficulties with the shape of the opening. All manner of panel materials are contemplated, including for example curable plastics, and masonry composites.

FIG. 12Ais a front perspective view of a panel assembly900having a piece of drywall910with a plastic insert922about the opening920. The drywall910is preferably shipped with a paper covering912around the outer edges for protection. The covering912can either be removed or left in place when finishing the drywall910to surrounding wall (not shown). The drywall910can advantageously include instructions, trademark markings, (collectively914), and so forth.

The insert922has a shallow lip922that extends out from the front side of the drywall910by about ⅛ inch to 1/16 inch, or in metric terms about 1-2 mm. Those distances are to be reasonable to provide a stop up to which an installer can feather a smooth edge of spackle or “mud”.

As best seen inFIG. 12B, insert922also has an attachment plate924that is recessed from the front side by about ½″, or in metric terms a little over 1 cm. Of course, other distances could alternatively be used for the recess. In this particular instance plate924has an optional level926that can be used by the installer to install the drywall910so that the plate924is level. Optional screws or bolts928can be used to tighten the insert922against the drywall910.

FIGS. 12C and 12Dshow the back of drywall910and insert922, including: the back side of the level926; optional protrusions921forming part of the logo; the open ends of screws or bolts928, which are seated in female threaded receivers929; and additional female threaded receivers927to receive bolts or screws (not shown) used to attach a speaker or other device (not shown) against the back of the plate924. Insert922can be glued against the drywall910using glue916, and the back side of the junction between the insert922and the drywall910can be covered with tape918to improve appearance.

FIG. 13is a schematic of steps in a method according to inventive concepts disclosed herein.