Abstract:
A receptacle for enclosing low-voltage electronic devices and maintaining the integrity of a vapor barrier. The receptacle forms a cavity having an open side. The receptacle may be mounted within a wall having a vapor barrier and an outer layer. The vapor barrier may be sealed to the receptacle and the outer layer and the vapor barrier may extend over the receptacle to enclose the space within the cavity, thereby forming an airtight enclosure.

Description:
This application is continuation application of U.S. patent application Ser. No. 10/677,020 filed Oct. 1, 2003, which is a continuation application of U.S. patent application Ser. No. 09/516,199 filed Feb. 29, 2000, now U.S. Pat. No. 6,660,936, which is a continuation application of U.S. patent application Ser. No. 09/193,876 filed on Nov. 18, 1998, now U.S. Pat. No. 6,031,181. 

   FIELD OF THE INVENTION 
   The present invention relates generally to components for building construction. More particularly, the present invention relates to receptacles for enclosing low voltage electronic devices. 
   BACKGROUND OF THE INVENTION 
   With the rising cost of energy, efforts have been made to provide homes and other buildings with insulation which will more efficiently prevent the loss of heat to the outside. Modem building techniques include the installation of a vapor barrier in the walls of homes or other buildings. 
   The vapor barrier contains warm, moist air inside the building. If warm air from inside the building penetrates the vapor barrier, moisture from this air may condense inside the walls and ceilings of the building. This condensed moisture can promote mold growth and cause building materials to degrade. The loss of warm air from the inside of the building to the outside of the building also increases the cost of heating the structure. 
   When mounting speakers, keypads and other low voltage electronic devices in the wall or ceiling of a house or other building it is desirable to protect the low voltage devices from exposure to dirt, debris from building materials and other substances which may cause these devices to deteriorate. Installers who place low-voltage electronic devices in the walls of structures often use standard building materials to fabricate a “custom-built” enclosure at the installation site. To comply with modern building requirements, these custom-built enclosures must be substantially impervious to warm, moist air, and they must be sealingly connected to the existing vapor barrier of the structure. A great deal of skill is required to assemble an enclosure at a work site which will accomplish these goals. Even when an installer is highly skilled, this task is very time consuming. 
   SUMMARY OF THE INVENTION 
   A receptacle enclosing low voltage electronic devices and maintaining the integrity of a vapor barrier. The receptacle includes a base and four side walls. Each side wall is joined to two adjacent side walls to form a perimeter wall. The perimeter wall is joined to the base and extends from it in a generally perpendicular fashion. The perimeter wall and base delineate a generally rectangular enclosure with five closed sides and one open side. 
   The base of the receptacle includes a pattern of concentric geometric shapes. When a portion of the base is seen through a hole cut in a wall, this pattern provides the installer with visual indicators which allow the installer to determine the location of the hidden portions of the receptacle. 
   The receptacle also includes a plurality of wire located dimples. The material thickness of the wire locator dimples is generally thinner than the thickness of the perimeter wall and the base. The wire locator dimples are useful for creating a hole which will allow a wire to enter the receptacle. Removing the wire locator dimple from the receptacle using a knife or other cutting tool creates a small circular hole in the receptacle. When the desired length of wire is pulled through the hole, the hole may be sealed using any commercially available sealant. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a perspective view of a receptacle for enclosing low voltage electronic devices in a wall; 
       FIG. 2  is a cross sectional view of a receptacle for enclosing low voltage electronic devices in a wall; 
       FIG. 3  is a plan view of a receptacle positioned inside a wall; 
       FIG. 4  is a plan view of an alternate embodiment of a receptacle positioned in a wall; 
       FIG. 5  is a third embodiment of receptacle positioned in a wall; 
       FIG. 6  is a cross sectional view of a wall with a receptacle for enclosing low voltage electronic devices positioned inside of it; and 
       FIG. 7  is a plan view of a wall with a hole cut through the wall for fastening a low voltage electronic device. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   Reference is now made to the figures, in which like element numbers refer to like elements throughout.  FIG. 1  is a perspective view of a receptacle shown generally by element number  10 . Receptacle  10  includes a base  12 , and four side walls  14 ,  16 ,  18 , and  20 . Each side wall is joined to two adjacent side walls to form a perimeter wall  11 . Perimeter wall  11  is joined to base  12  and extends from base  12  in a generally perpendicular fashion. Perimeter wall  11  and base  12  delineate a generally rectangular enclosure with five closed sides and one open side. 
   A mounting flange  22  is joined to side walls  14 ,  16 ,  18 , and  20 . Mounting flange  22  is comprised of side flanges  24  and  26 , top flange  28  and bottom flange  30 . Flanges  24 ,  26 ,  28 , and  30  extend in a generally perpendicular fashion from side walls  14 ,  16 ,  18 , and  20  respectively. 
   Base  12  includes a pattern of concentric geometrical shapes shown generally at  32 . As shown in  FIG. 1 , the center of pattern  32  is generally aligned with the center of base  12 . Pattern  32  in  FIG. 1  is a pattern of concentric circles. It is to be understood that another geometric shape could be chosen for pattern  32  without deviating from the spirit or scope of this invention. For example, pattern  32  could be a pattern of polygons, such as triangles, or squares. 
   Pattern  32  may also be created on base  12  using a variety of techniques. For example, pattern  32  could be injection molded with a series of raised lines which constitute pattern  32 . Alternately, pattern  32  could be printed on a label and the label could be adhered to base  12 . Pattern  32  could also be printed directly onto base  12  using conventional printing methods such as pad printing or screen printing. 
   In a preferred embodiment, pattern  32  is formed by alternating ridges  34  and grooves  36  in base  12  (best shown in  FIG. 2 ). Ridges  34  and grooves  36  serve to stiffen base  12  in addition to creating pattern  32 . Stiffening of base  12  is particularly valuable when receptacle  10  is used to house audio speakers. If base  12  was substantially flexible, an audio speaker may cause it to vibrate and create undesirable noise. 
   Receptacle  12  includes a plurality of wire locator dimples  33 A,  33 B,  33 C,  33 D, and  33 E. As best shown in  FIG. 2 , wire locator dimples  33 A,  33 B,  33 C,  33 D, and  33 E each are comprised of a localized projection formed from the same material as the wall but extending away from the wall. The material thickness of wire locator dimples  33 A,  33 B,  33 C,  33 D, and  33 E is generally thinner that the material thickness of side walls  14 ,  16 ,  18 , and  20 , and base  12 . 
   Wire locator dimples  33 A,  33 B,  33 C,  33 D, and  33 E are useful for creating a hole allowing a wire  62  to pass through one wall of receptacle  10 . For example, if an installer intends to pass wire  62  through wall  20 , a knife or other cutting tool may be used to cut off wire locator dimple  33 D. Cutting off wire locator dimple  33 D creates a small circular hole in wall  20 . When installing a low-voltage electronic device in receptacle  10  wire  62  will be pulled through this hole. When the desired length of wire  62  is pulled through the hole, the hole will be sealed using any commercially available sealant such as silicone caulk or acrylic caulk. Sealing the hole which allows wire  62  to enter receptacle  10  is necessary in order to maintain a continuous vapor barrier within wall  50 . Wire locator dimples  33 A,  33 B,  33 C,  33 D, and  33 E allow an installer to quickly create a small round hole of uniform size and shape. Only a small amount of sealing material is require to seal this small uniformly shaped hole after wire  62  has been positioned. This saves time for the installer and improves the integrity of the vapor barrier. 
   In one embodiment of receptacle  10 , a layer of pressure sensitive adhesive  38  is applied to flange  22  as shown in  FIG. 2 . Pressure sensitive adhesive  38  may be covered with a release liner  40  to prevent pressure sensitive adhesive  38  from adhering to any objects while receptacle  10  is transported and stored prior to use. Release liner  40  may be comprised of a layer of paper or plastic film treated with a release agent. Release liner materials of this type are well known in the art and may use silicone or fluoropolymer based release agents. 
   Receptacle  10  may be made from any substantially rigid material. The preferred material for receptacle  10  is a thermoplastic material such as ABS or PVC. Thermoplastic materials are low in cost and they can be easily fabricated using conventional injection molding, or thermoforming processes. In many applications a flame-retardant thermoplastic material will be preferred. 
   A portion of a building wall  50  is illustrated in  FIG. 3  with the inventive receptacle  10  installed. Wall  50  includes structural members  52 A,  52 B, and outer layer  54 . Structural members  52 A,  52 B may be comprised of a number of commonly used building materials including steel, aluminum, and wood. A number of materials may also be used to fabricate outer layer  54  including plaster, wood, acoustic tiles, gypsum board, or a wood fiber composite material. In the art gypsum board is sometimes referred to as drywall, or by the trademarked brand name SHEETROCK. A barrier film  56  is positioned directly behind outer layer  54  in wall  50 . Barrier film  56  may be any low cost, thin material which is substantially impervious to air and water vapor. Barrier film  56  is positioned in wall  50  to prevent the passage of warm moist air from the inside of the building to the outside of the building. To accomplish this goal completely, any holes made in barrier film  56  is preferably completely sealed. In the art the walls of a building are assembled to include a continuous sealed layer which is comprised of multiple sheets of barrier film  56  sealingly attached along their edges. In the art, this continuous sealed layer is referred to as the vapor barrier. An objective of the present invention is to provide method of installing low-voltage electronic devices in a wall while maintaining the integrity of the vapor layer. 
   Receptacle  10  is positioned in wall  50  so that side flanges  24  and  26  overlap structural members  52 B and  52 A respectively. A plurality of fasteners  58  have been used to attach side flanges  24  and  26  to structural members  52 B and  52 A. In the embodiment shown in  FIG. 3  fasteners  58  are depicted as staples, however it should be understood that other fasteners could be used without departing from the spirit and scope of this invention. For example, fasteners  58  could be screws, nails, or rivets. 
   In an alternate embodiment receptacle  10  may be positioned in wall  50  so that top flange  28  and bottom flange  30  overlap structural members  52 A,  52 B. In a preferred embodiment the length of side walls  14 ,  16 ,  18 , and  20  are selected so that receptacle  10  will fit between structural members  52 A,  52 B which have be placed a distance part which is commonly used in the art. For example, the length of side walls  18  and  20  may be selected so that receptacle  10  will fit between structural members which have been placed on 16 inch centers and the length of side walls  14  and  16  may be selected so that receptacle  10  will fit between structural members which have been placed on 24 inch centers. 
   An end  60  of wire  62  is disposed inside receptacle  10 . Wire  62  passes through a wire entry hole  61  in side wall  18  of receptacle  10 . A wire coil or bundle  64  is formed of wire  62  and is disposed immediately outside one wall of receptacle  10 . Although  FIG. 3  illustrates wire  62  passing through side wall  18 , it should be noted that wire  62  may pass through any side wall  14 ,  16 ,  18 ,  20 , or base  12  without departing from the scope or spirit of this invention. 
   It should also be noted that although the specific embodiment illustrated in  FIG. 3  depicts receptacle  10  installed in a wall, receptacle  10  may be installed in other portions of a building without departing from the spirit or scope of this invention. For example, receptacle  10  may be mounted in a ceiling to house an audio speaker. 
     FIG. 4  is a plan view illustrating a receptacle  110 . Receptacle  110  is positioned in wall  150  so that side flanges  124  and  126  overlap structural members  152 B and  152 A respectively. A plurality of fasteners  158  have been used to attach side flanges  124  and  126  to structural members  152 B and  152 A. 
   A wire  162  extends through a wire entry hole  161  in side wall  118  of receptacle  110 . A wire bundle  164  and a wire end  160  are both disposed inside receptacle  110 . Wire entry hole  161  was created by cutting off a wire locator dimple (not shown). Wire entry hole  161  is covered by seal  166  which is adhesively bonded to both wire  162  and wall  118  of receptacle  110 . Seal  166  is created by dispensing a sealant  168  onto both wire  162  and wall  118  in the vicinity of wire entry hole  161 , then allowing sealant  168  to cure. Sealant  168  may be any one of a number of commercially available materials including silicone caulk and acrylic caulk. Seal  166  ensures the integrity of the vapor barrier by closing wire entry hole  161  which was made in wall  118  to accommodate wire  162 . 
   A plurality of mounting brackets  172 ,  174  are disposed in receptacle  110 . Mounting brackets  172 ,  174  may be attached to receptacle  110  with mechanical fasteners (not shown) such as rivets or screws. Mounting brackets  172 ,  174  may also be adhered to receptacle  110  with an adhesive (not shown). Mounting brackets  172 ,  174  provide a convenient place to attach low-voltage electronic devices which are being housed in receptacle  110 . 
     FIG. 5  is a plan view of a receptacle  210  positioned in a wall  250 . A wire  262  extends through seal  268  and through a wire entry hole  261  in a side wall  218  of receptacle  210 . Seal  266  is adhesively bonded to both wire  262  and wall  218 . Seal  266  is created by dispensing a sealant  268  onto both wire  262  and wall  218  in the vicinity of wire entry hole  261 , then allowing sealant  268  to cure. Sealant  268  may be any one of a number of commercially available materials including silicone caulk and acrylic caulk. 
   A zig/zag or serpentine wire pattern  270  is disposed inside of receptacle  210 . Serpentine wire pattern  270  is comprised of a length of wire  262  which has been bent into the shape shown in the  FIG. 5 . Fasteners  269 , such as staples preferably loosely hold wire pattern  270  in place until the electronic device is installed. 
     FIG. 6  is a section of wall  50  taken along section line A—A in  FIG. 3 . Receptacle  10  is illustrated in  FIG. 6  in a position between structural members  52 A and  52 B. Barrier film  56  is shown covering receptacle  10 . Flange  22  of receptacle  10  is sealingly connected to barrier film  56 . A number of methods may be used to accomplish this seal. In one embodiment pressure sensitive adhesive layer  38  is pre-applied to flange  22  and covered with release liner  40 . Release liner  40  is removed prior to covering receptacle  10  with barrier film  56 . When barrier film  56  is positioned over receptacle  10  it will readily adhere to pressure sensitive adhesive layer  38  and form a sealed connection with flange  22 . 
   An alternate method for sealing barrier film  56  to flange  22  is to apply an adhesive to flange  22  just prior to covering receptacle  10  with barrier film  56 . Spray on adhesives suitable for this purpose are commercially available from 3M Company (St. Paul, Minn.). Finally, sealing tape may also be use to seal barrier film  56  to flange  22 . 
     FIG. 7  is a plan view of wall  50  taken from the point of view of line B—B shown in  FIG. 6 . A hole  80  has been cut through outer layer  54  and barrier film  56 . Geometric pattern  32  of receptacle  10  is visible through hole  80 . Geometric pattern  32  provides the installer of a low voltage electronic device with a visual reference point. After looking at geometric pattern  32 , the installer knows which direction he or she must reach to find wire end  60 . 
   Referring to  FIG. 7  and  FIG. 3 , the preferred steps used to enclose a low-voltage electronic device and maintain the integrity of a vapor barrier are as follows: 
   1. Choose which of the wire locator dimples is the most convenient place for wire  62  to enter receptacle  10 . 
   2. Cut off the wire locator dimple to create wire entry hole  61 . 
   3. Position receptacle  10  within wall  50  so that at least one flange is in direct contact with a structural member. 
   4. Secure the flange to the structural member. 
   5. Thread wire  62  through wire entry hole  61  in receptacle  10 . 
   6. Place barrier film  56  over structural members  52 A,  52 B and receptacle  10 . 
   7. Seal barrier film  56  to flange  22  of receptacle  10 . 
   8. Complete the assembly of the wall by positioning outer layer  54  over barrier film  56 . 
   9. Connect a radio frequency transmitter to wire  62 . 
   10. Use a radio frequency receiver to determine the approximate location of wire end  60 ; in this approximate location, create hole  80  through barrier film  56  and outer layer  54 . 
   11. Visually examine pattern  32  to determine the location of wire end  60  relative to hole  80 . 
   12. Reach inside hole  80  with one hand and retrieve wire  62  by grasping wire end  60 . 
   13. Pull out the desired length of wire  62  and attach wire end  60  to the low-voltage electronic device which is being installed. 
   14. Seal wire entry hole  61  in enclosure  10  using a sealant such as silicone caulk or acrylic caulk. 
   15. Complete the installation by fastening the low-voltage electronic device to outer layer  54 . 
   Numerous advantages of the invention covered by this document have been set forth in the foregoing description. It will be understood, however, that this disclosure is, in many respects, only illustrative. Changes may be made in details, particularly in matters of shape, size, and arrangement of parts without exceeding the scope of the invention. The inventions&#39;s scope is, of course, defined in the language in which the appended claims are expressed.