Abstract:
A wall plate assembly including a wall plate with an integrated USB module. The assembly includes a USB connector and printed circuit board formed together on the wall plate as an integral whole. By placing USB extender circuitry directly on the printed circuit board, rather than in a separate housing, the present assembly can maintain its bus-powered attributes without the bulk of a separate extender housing. A quick-connect coupling enables fast electrical connection and disconnection with a complementary quick-connect coupling on a USB wire.

Description:
[0001]    This is a continuation application of co-pending (and now allowed) application Ser. No. 11/967,335 filed on Dec. 31, 2007, entitled WALL PLATE ASSEMBLY WITH INTEGRAL UNIVERSAL SERIAL BUS MODULE. This application claims the benefit of the filing date of U.S. Provisional Application No. 60/944,916, filed Jun. 19, 2007. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    The present invention relates generally to wall plates used to convey electric signals through premise wiring systems, and more particularly to a wall plate assembly with an integrated universal serial bus (USB) module for USB extension without the need for an external power supply. 
         [0003]    USBs are an increasingly popular way to connect computers to peripheral devices, such as data input/output, portable memory devices and audio/visual equipment. By placing the issues associated with linking dissimilar devices into on-board software (or protocol), the USB makes connection between a hub (or source) and function (or device). USBs can be powered so that they regenerate signals, thereby allowing great lengths between hub and function devices. 
         [0004]    Wall plates are commonly used to terminate premise wiring. In one general form, the wiring acts as a signal carrier for electrical signals, while in a specific form is capable of conveying audio, video and related data signals between a signal source (such as a computer, audio, video or combination device) and the wall plate. Audio, video and data devices (such as displays, monitors, digital video disk (DVD) players, compact disk (CD) players, video tape recorders or the like) can be plugged into the outlet of the wall plate to complete the signal path. These, as well as other device that may employ USB electronics, connections and related circuitry, may be placed at distances remote from a host, often at distances far greater than that which a USB signal is able to extend. 
         [0005]    In such circumstances, it may be necessary to boost or otherwise extend the USB signal. In one form of signal extension, the USB electronics are coupled to an external power source, such as a conventional AC source in what is referred to as a self-powered configuration. Such coupling allows the needed increase in range, but does so through additional wiring that may be prohibitive from a space, cost and related complexity perspective. In another form, the USB electronics draw all of their needed power from the USB connection itself, in what is known as a bus-powered configuration. Typically, the USB electronics are incorporated into one or more separate modular units that provides the extension in range, and includes a transmitter unit (for example, at the host end) and a receiver unit (for example, at the device end). Each unit is in turn connected to a wall plate so that devices requiring USB connection can do so through the wall plate. While useful for its intended purpose, such designs are problematic in that special attachment schemes between the USB electronics and the wall plate are necessary. For example, dongle and related connectivity cables are required. As with the external-powered approach discussed above, the self-powered approach makes the wall plate assembly bulky and expensive. In either approach, the presence of separately attached, exposed and removable components also renders the wall plates susceptible to damage during transport, installation nor the like. 
         [0006]    It is therefore desirable that a more efficient, lower-cost, more reliable approach to connecting USB equipment through a wall plate be developed. It is additionally desirable that a compact, easy-to-use wall plate assembly incorporating self-powered USB features for extended range be developed. It is further desirable that an approach to packaging USB signal-extending circuitry such that the circuitry is an integral part of a wall plate assembly. 
       BRIEF SUMMARY OF THE INVENTION 
       [0007]    These desires are met by the present invention, where a wall plate assembly and a method of connecting USB-compatible wiring is disclosed. According to a first aspect of the invention, a wall plate assembly includes USB-compatible hardware and related circuitry mounted onto a wall plate such that the wall plate and module define a single unit that is mechanically and electrically integrated. In the present context, disparate components, members, devices or related equipment are considered to define a mechanically integrated or integral whole or unit when such components are combined in such a way as to make them rigidly secured to one another such that they are integral in a functional sense. Means such as fastening and welding may be indicative of such integral structure if, as a result of such fastening, welding or the like, they produce an article that is of substantially unitary or one-piece construction. Generally, the presence of separate, readily removable and attachable components (such as hand-connected dongle cables or related wires, as well as those components situated on an outer surface or periphery of the unit) would be destructive of such an integral construction. Similarly, separate components are considered to be electrically integrated when the connection between them is through predominantly non-separable components. Thus, cables with quick-connect or related non-permanent features are considered to be non-integral, whereas hardwired, adhesively mounted, soldered or trace-connected (such as on a printed circuit board) components are considered to be integral. 
         [0008]    The wall plate assembly includes a wall plate defining a face (for example a front face) with one or more USB connectors formed in the face, a wall mounting member, a circuit board and a housing configured to substantially contain the circuit board. The circuit board includes USB extender circuitry and an electrical interface extending from the circuit board and cooperative with the extender circuitry such that upon coupling of the interface to a first USB-compatible component, a signal may be operated upon by the extender circuitry while being transmitted between first and second USB-compatible components, where one is connected directly to the connector and the other directly to the interface. In the present context, the term “substantially” refers to an arrangement of elements or features that, while in theory would be expected to exhibit exact correspondence or behavior, may, in practice embody something less than exact. As such, the term denotes the degree by which a quantitative value, measurement or other related representation may vary from a stated reference without resulting in a change in the basic function of the subject matter at issue. By having the extender circuitry be directly secured both electrically and mechanically to one or more other components within the assembly, such as the connector, mounting member, wall plate, circuit board or housing, it takes on an integrated structure not possible with configurations where the circuitry can be readily attached and detached. 
         [0009]    Optionally, the wall mounting member is configured as a bracket that can mount to a wall structure by accepting a fastener through it. The extender circuitry can be formed on the circuit board, or can be mounted directly to the circuit board. In either event, it is desirable to avoid cables with quick-connect and other relatively non-permanent connectivity. In one form, the wall mounting member and the wall plate are formed as a unitary structure, while in another, they can be permanently affixed to one another. In the present context, terms implying “permanent” or “semi-permanent” connectivity between components include situations where that which is joined is not intended on becoming separated such that in the process of such separation, damage is done to either or both of them, or the structural or electrical properties are defeated or at least severely curtailed. The assembly may further include one or more posts extending between the circuit board and the wall plate to create a spaced relationship between them. In another optional form, the wall plate, wall mounting member, circuit board and housing are rigidly affixed to one another. The housing may be formed around the printed circuit board on the back of the wall plate such that it defines a substantially closed, rectangular containment (such as a simple box). Furthermore, the box may be made from an inexpensive, lightweight material (such as plastic), or may be made from a metal-based material so that the housing acts as an electromagnetic shield that can substantially enclose the circuit board. In either material configuration, it also has an aperture formed therein to allow the rear coupling to be easily accessed by a jack or related terminus point of USB wiring being fed to the wall plate assembly. The housing may additionally define a recess in the housing&#39;s otherwise substantially rectangular shaped outer dimension. In this way, the aperture discussed above defines a cutout for the coupling. The extender circuitry may be permanently affixed to the circuit board or connector. The assembly may also include one or both of a transmitter and a receiver so that USB signals coming into or leaving the assembly can be appropriately conveyed. 
         [0010]    According to another aspect of the invention, a bus-powered USB wiring system is disclosed. The system includes an assembly generally similar to that discussed in the previous aspect, and further includes at least one wire, cable or similar electrically-conductive signal carrier to convey a USB-compatible signal. The wire has a proximal end configured to connect to a USB host and a distal end configured to connect to a USB device. The assembly includes a wall plate defining a face with one or more USB connectors formed in it. The assembly further includes a wall mounting member (for example, a bracket) and a circuit board connected to one or both of the wall plate and the wall mounting member. The circuit board includes USB extender circuitry and an electrical interface, where the latter is mounted to or otherwise extends from the circuit board so that upon coupling of the interface to the wire, a signal that is transmitted between the host and device through the wire may be operated upon by the extender circuitry while passing through the wall plate assembly. The extender circuitry is electrically coupled to one of the connector and the interface such that it receives its operating electrical power from a respective one of the host and device. In addition, the assembly includes a housing that acts as an enclosure or container for the circuit board, extender circuitry and electrical interface. The housing may include cutouts or apertures formed therein to allow connection of the wire to the interface and circuit board. 
         [0011]    Optional features include connecting numerous wall plate assemblies together. In addition, one of the wall plate assemblies may further include or be connected to a transmitter, while a second may include or be connected to a receiver. In one form, the transmitter is placed serially upstream of the receiver. For example, if the wiring is used to support a computer system, the transmitter can be located at or with the computer such that one or more wall plate assemblies can include receivers and be linked to the transmitter through appropriate cable or related wiring. The wire used to convey the USB-compatible signal may be an industry-standard variety, such as an RJ CAT 5 cable. 
         [0012]    According to another aspect of the invention, a method of connecting USB-based components through a wall plate assembly is disclosed. The method includes arranging the wiring to include a quick-connect coupling that can be connected to a complementary quick-connect coupling situated on a wall plate assembly. The wall plate assembly includes (in addition to the complementary coupling) a USB module mounted to a wall plate such that the module and plate form an integral whole. Optionally, connection between the wall plate assembly to one or more USB wires can be through complementary quick-connect couplings. Such coupling may be permanently attached to the USB module, which is preferably formed on or as part of a printed circuit board. 
         [0013]    Optionally, the method further includes securing at least one of the wall plate, wall mounting member and circuit board to a housing; in this way, the housing can substantially contain the circuit board. In another particular form, electric power can be provided to the wall plate assembly from the host. More particularly, the first component can be a computer, including desktop, laptop or other related variants. The second component (which is preferably associated with the device) can be a printer, video display, cellular telephone, digital camera, scanner, bar code reader, modem, personal digital assistant and an integrated services digital network (ISDN) terminal adapter. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         [0014]    The following detailed description of specific embodiments of the present invention can be best understood when read in conjunction with the following drawings, where like structure is indicated with like reference numerals and in which: 
           [0015]      FIG. 1  illustrates a schematic view of a wall plate assembly with USB connectivity according to one form of the prior art; 
           [0016]      FIG. 2A  illustrates a forward view of a wall plate assembly with separately attached USB electronics according to another form of the prior art; 
           [0017]      FIG. 2B  illustrates a rearward view of the wall plate assembly of  FIG. 2A , highlighting the separate USB extender; 
           [0018]      FIG. 3A  illustrates a generally rearward view of a wall plate assembly according to an embodiment of the present invention, shown coupled to a USB wire; 
           [0019]      FIG. 3B  illustrates a rearward perspective view of the wall plate assembly of  FIG. 3A ; 
           [0020]      FIG. 4A  illustrates a front view of a wall plate according to an aspect of the present invention with a Type A USB connector; 
           [0021]      FIG. 4B  illustrates a side view of the wall plate of  FIG. 4A ; 
           [0022]      FIG. 4C  illustrates the side view of the wall plate of  FIG. 4A  with a housing covering the back thereof; 
           [0023]      FIG. 4D  illustrates a front view of a wall plate according to an aspect of the present invention with a Type B USB connector; 
           [0024]      FIG. 4E  illustrates a side view of the wall plate of  FIG. 4D ; 
           [0025]      FIG. 4F  illustrates a side view of the wall plate of  FIG. 4D  with a housing covering the back thereof; 
           [0026]      FIG. 5  shows a house using premise wiring and one embodiment of the wall plate assembly of the present invention; and 
           [0027]      FIG. 6  shows a USB-compatible wiring system according to an embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0028]    USB-configured wall plates can be used to provide asymmetric connectivity between a USB-compatible host and a USB-compatible remote device, as well as act as a hub for numerous USB ports in versions that include numerous connectors. In this latter configuration, they can function in a manner generally similar to external (i.e., stand-alone) USB hubs. In any event, USB-configured wall plates generally include self-power or bus power, as previously discussed. Referring first to  FIG. 1 , the assembly of a wall plate  10  according to a self-powered form of the prior art is shown. The wall plate  10  includes a first (forward-facing) surface, second (i.e., rearward-facing) surface, a printed circuit board  12  and USB hub circuit  14  mounted thereto. A USB connector  22  extends from the printed circuit board  12  through the first and second surfaces of the wall plate  10 , as does an indicator light  24 . The USB hub circuit  14  is structured to permit numerous USB devices to be connected together and to a host computer USB port or another hub circuit (neither of which are shown). Although the wall plate  10  is shown with a single USB connector  22 , it will be appreciated by those skilled in the art that USB hub circuit  14 , operating in conjunction with numerous USB connectors  22  formed in the forward-facing surface of wall plate  10 , can be used to connect multiple USB devices. It will also be appreciated by those skilled in the art that a variant of the wall plate  10  without a USB hub circuit may also be employed for situations where the need for multiple connectors or ports is not present. 
         [0029]    As mentioned above, the configuration such as that depicted in  FIG. 1  is referred to as a self-powered wall plate in that receives electrical power from external power supply  18  that feeds a transformer  20  and local USB power supply  16 . The entire assembly may be placed inside a junction box (not shown) that in turn may be mounted within an opening formed in a wall (not shown). The combination of the external power supply  18 , transformer  20  and local USB power supply  16 , while allowing USB range to be extended, occupies a significant amount of volume in the assembly, as separate lines to provide the external power are needed. Thus, while such a configuration can be used for multiple USB devices, the additional wiring associated with the power supply  18 , coupled with the wiring needed for the numerous connectors or ports, causes significant increases in size or complexity. 
         [0030]    Referring next to  FIGS. 2A and 2B , the assembly of a wall plate  50  according to the bus-powered form of the prior art is shown. As with the self-powered version discussed above, wall plate  50  allows a USB to be extended over greater operating lengths, as without the signal boosting made possible by the externally-powered USB connection of  FIG. 1 , or the bus-powered version shown in  FIGS. 2A and 2B , the length of wiring used to establish the connection is limited, typically to around five meters in length. A USB extender  62 , such as that shown in with particularity in  FIG. 2B  and discussed in more detail below, can increase the length between a USB host and device by up to one hundred and fifty feet or more, as can the device of  FIG. 1 . Referring with particularity to  FIG. 2A , a first (forward-facing) surface  50 A is shown with various connectors mounted therein, including a network connector  54 , computer connector  56 , audio connector  58  and USB connector  60  of the Type B variety. Power for the USB is delivered through USB connector  60  from a host, such as a computer (not shown). 
         [0031]    Referring with particularity to  FIG. 2B , a second (rearward-facing) surface  50 B is shown with the rearward portions of the network, computer, audio and USB connectors  54 ,  56 ,  58  and  60  projecting therethrough. The USB extender  62  is in the form of a self-contained modular unit that is attached to the rearward-facing surface  50 B, and acts as a receiver to accept appropriate USB signals from a complementary transmitter (not shown). Such an extender may function in a manner generally similar to that of the device of  FIG. 1 , with the exception of how it derives its operating power, where instead of taking power from an external source, it takes it from the upstream USB host. In addition to containing extender circuitry, the USB extender  62  may also include DC power conditioning circuitry in order to ensure proper voltage is delivered to the remote device. 
         [0032]    A separate dongle cable  64  is used to establish electrical connectivity between the USB connector  60  and the USB extender  62 . The dongle cable  64  terminates on at least one end with a quick-connect coupling. USB extender  62  is not integrated into wall plate  50 , as it is secured (if at all) to the rear surface of wall plate  50  through a limited contact, which may be glued, fastened (such as by screws that extend through the wall plate  50  and into complementary threads formed in the USB connector  62 ), snap-fit or otherwise mechanically joined together. By these features, the wall plate  50  is not truly integrated, in that while it possesses the equipment necessary to establish signal connectivity between a host and device, the modular, removable nature of the connection between the wall plate  50  and the USB extender  62  belies a lack of permanence that is associated with integration. Furthermore, the dongle cable  64  is packaged in such a way as to leave exposed many of the delicate connecting features. For example, dongle cable  64  is left exposed, such that upon installation or transport, its signal connection between the USB connector  60  and USB extender  62  is susceptible to damage or becoming disconnected. Further, the length of the dongle cable  64  (which my be up to six inches or more) is such that it can extend beyond the footprint of the wall plate  50 , thereby making the installer&#39;s job more difficult. It is worth noting that merely covering the exposed components, such as dongle cable  64  and USB extender  62 , with a junction box or related cover is not sufficient in and of itself to establish the requisite degree of integration, as their degree of connectivity to at least each other, as well as to wall plate  50 , would remain unchanged. 
         [0033]    Referring next to  FIGS. 3A and 3B , the back (or rear) side of a wall plate assembly  100  according to an aspect of the present invention is shown. In it, a wall plate  110  is shown supported by the mounting bracket (also referred to as a wall mounting member)  120 . The bracket  120  includes apertures that allow a screw or related fastener to pass therethrough for engagement with a stud, wall board or other structural member in the wall. A housing  130  with partial recess  135  is used to contain components of assembly  100  inside. Wiring  150  (shown presently as twisted pair) supplies signals from a host or other device (neither of which are shown) to the assembly  100 , connected through a jack  160  that is shaped to mechanically cooperate (such as by snap-fit or other resilient connection) to an electrical interface  195  (also known as an outlet, described below) formed on a printed circuit board  180  such that it can cooperate with wiring  150  and jack  160  through a cutout formed in recess  135 . The nature of the recess  135  is such that when external wiring  150  and ancillary connectors (such as jack  160 ) engage the housing  130 , they do so without increasing the footprint of wall plate assembly  100 . By having housing  130  contain all of the electrical USB and related signal connectors, ports and associated wiring, the robustness of assembly  100  is enhanced, as the likelihood of damage during installation is reduced by the presence of a rigid structure with electrical connections achieved through relatively-unexposed flush mounting. Unlike the non-integrated configurations of the prior art, circuit board  180  preferably includes the USB extender circuitry directly thereon, thereby minimizing the chance of disparate components and their connections from coming apart during shipping, storing or installation. 
         [0034]    Referring next to  FIGS. 4A through 4F , front and side views of the wall plate assembly of  FIGS. 3A and 3B  are shown, where one of each of the side views shows the wall plate  110  with the housing  130  attached, and the other without, the latter thereby exposing the printed circuit board  180  and a coupling in the form of electrical interface  195  that is compatible with jack  160  such that the two form a snap-fit or related connection. Printed circuit board  180  is mounted to either the bracket  120  or to the rear surface of the wall plate  110  (this latter configuration as shown in the side views) through posts  190 . Soldering, adhesives, friction fit or related connection can be used to promote an integral relationship between the printed circuit board  180  and wall plate  110  or bracket  120 . Housing  130  is mounted to either or both of the bracket  120  and wall plate  110  through a series of fasteners  140  (which may be in the form of screws, rivets, adhesives or the like), while the electrical interface  195  and USB extender electronics are mounted to or formed in printed circuit board  180  in such a way as to form an integrated whole with one or more of the bracket  120 , wall plate  110  and housing  130 . 
         [0035]    As can be seen in the side views, the USB connectors (collectively  170 , but shown as a Type A connector  170 A in  FIGS. 4A through 4C  and a Type B connector  170 B in  FIGS. 4D through 4F ) extend through the wall plate  110  to allow user access to the front side of the wall plate  110 . Although Type A and Type B connectors are shown, it will be appreciated by those skilled in the art that other USB-compatible connectors may be used, such as micro USB connectors and mini USB connectors. Either of the connectors  170 A,  170 B are also electrically connected to the electrical interface  195  through the printed circuit board  180  such that signals generated by a USB host are passed to a USB device through the connectors  170 A,  170 B, printed circuit board  180  and electrical interface  195 , the last of which includes a proximal end and a distal end, where the proximal end is in electrical communication with the printed circuit board  180 , while distal end electrically connects to the jack  160 , such as shown in  FIGS. 3A and 3B . The printed circuit board  180  may contain (or have mounted thereon) the USB electronics and related circuitry, such as DC conditioning circuits or the like. The quick-connect nature of the electrical interface  195 , such as by a resiliently biased spring or related snap-fit connection  161 , provides a secure and fast coupling with the mating quick-connect electrical connector of the jack  160 . 
         [0036]    One valuable attribute of the wall plate  110  of the present invention is its modularity made possible by its integral, self-contained construction. The housing  130  may be formed from a plastic case (for example, a gang box, also referred to as a junction box) that also houses the terminus point (for example, the distal end of the electrical interface  195 ) of USB wiring  150 . Other materials (for example, metal) may be used to provide additional capabilities as needed. For example, in situations requiring an enhanced level of electromagnetic shielding, a metal housing  130  may be used. Although shown for a single USB connector  170 , it will be appreciated by those skilled in the art that additional electrical interfaces (not shown) and associated cutouts (also not shown) may be employed in the integrated approach discussed herein. 
         [0037]    Printed circuit board  180  is of a generally planar construction and is fabricated by techniques well-known to those skilled in the art. The electronics that make up the USB extender may be mounted to or formed on the circuit board  180 , thereby removing the need for a separate modular container, such as that shown in  FIG. 2B . In one form, the circuit board  180  is substantially coextensive with the wall plate  110  or bracket  120  to better enable the incoming wiring  150  and accompanying jack  160  to line up with the appropriate wiring or circuitry on the circuit board  180 . The circuit board  180  can be encased in the aforementioned housing  130 , and by virtue of its direct connection between the USB connector  170  and the electrical interface  195 , reduces the likelihood of wiring disconnects under normal shipping and installation. For example, the need for a separate dongle or related cable is removed, thereby avoiding the difficulty of keeping such components connected to one another during installation and use. By having the USB electronics formed on the printed circuit board  180 , which is in turn integral with the bracket  120 , wall plate  110  and housing  130  within the wall plate assembly  100 , reliable, volumetrically efficient USB connectivity is promoted. 
         [0038]    Referring next to  FIGS. 5 and 6 , the placement of integral wall plate assemblies  100  within a wiring system in a dwelling  200 , as well as a notional bus-powered USB wiring system according to an embodiment of the present invention is shown. Referring with particularity to  FIG. 5 , while the term “dwelling” is shown as a home, dormitory, apartment or other residence where people live, it will be appreciated that it may also be used to describe an office, factory, classroom or other commercial, institutional or manufacturing facility where people learn, work or the like. The wiring system can be responsive to input from an electrical device, such as a central control panel  230  (which may be connected to a multimedia system  240  or the like) or computer  210 , the latter acting as a transmitter of USB signals. As shown, wall plate assemblies  100  can form either a terminus point or an intermediary point within wiring system. One form of device that can benefit from a USB connection according to the present invention is a monitor  220 . Monitors  220  can be placed in various locations within dwelling  200  to facilitate the transmission of various signals (for example, audio/visual signals). In another form (not shown), computer peripheral equipment, such as printers, monitors or the like, can be placed remotely relative to the computer  210 . Referring with particularity to  FIG. 6 , wall plate assemblies  100  are connected between a transmitter shown in the form of the USB-compatible computer  210 , and a receiver shown in the form of a USB hub  310 , although it will be appreciated that the receiver can be any number of USB-compatible devices, such as hard drive enclosure, printer, projector, white boards or the like. USB-compatible wiring  150  (for example, the aforementioned RJ45 CAT 5 cable) is used to interconnect the various devices. In the form shown, one of the wall plate assemblies  100  includes a USB Type B connector  170 B signally adjacent the source provided by computer  210 , while another of the wall plate assemblies  100  includes a USB Type A connector  170 A signally adjacent the (receiver) device  310 . 
         [0039]    Having described the invention in detail and by reference to specific embodiments thereof, it will be apparent that modifications and variations are possible without departing from the scope of the invention defined in the appended claims. More specifically, although some aspects of the present invention are identified herein as preferred or particularly advantageous, it is contemplated that the present invention is not necessarily limited to these preferred aspects of the invention.