Abstract:
A frame assembly for mounting recessed fixtures that can be manually installed without the use of tools. One embodiment of the invention includes a primary mounting frame for recessed installation, the primary mounting frame defining an open interior to accommodate a fixture and including a border flange along the outer edge of the open interior. A ratcheting fastener is rotationally coupled to the primary mounting frame and can be manually secured by depressing it toward the border flange to secure the primary mounting frame between opposite surfaces of a substrate. The ratcheting fastener can be rotated to engaged or disengaged from ratcheting teeth.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
   This non-provisional United States (U.S.) patent application claims the benefit of provisional U.S. Patent Application No. 60/497,752, filed Aug. 26, 2003; and is related to U.S. patent application Ser. No. 10/871,069 filed on Jun. 18, 2004 by inventor Doug S. Wright, titled “Snap-In and Lock Baffle”, and is also related to U.S. patent application Ser. No. 10/871,111 filed on Jun. 18, 2004 by inventor Doug S. Wright, titled “Angled Speaker Assembly.” 

   FIELD 
   Various embodiments of the invention pertain to mounting assemblies. More particularly, at least one embodiment of the invention relates to a device, system, and method for efficiently mounting a speaker frame assembly within a wall or ceiling recess. 
   DESCRIPTION OF RELATED ART 
   Speakers, vents, exhaust fans are often mounted within a wall or ceiling cavity or recess. A frame assembly is commonly used to secure the speakers, vents, and/or exhaust fans to the wall or ceiling. Various types of frames and fasteners are used for the purpose of securing the frames to the wall or ceiling cavities. 
   Some conventional mounting systems are pressure fitted into the ceiling or wall cavity. However, this type of mounting system is undesirable because it does not provide a safe or strong way of securing devices such as speakers and exhaust fans. Other conventional fastening methods require the use of tools to turn a fastening screw. This is cumbersome and inconvenient in many cases. For example, when installing a recessed speaker within a ceiling cavity the installer would have to hold the frame in place with one hand while trying to turn a screw to secure the frame in place. Moreover, conventional frame fastening systems are not easy to remove and/or replace when maintenance may be required. 
   Consequently, conventional mounting systems and fasteners are typically cumbersome and time-consuming to install, take many steps to mount, and require the use of several tools. This increases the cost of installation and deployment of, for instance, recessed speakers, lights, or exhaust fans. 
   SUMMARY 
   One embodiment of the invention relates to a speaker mounting assembly having a primary mounting frame for recessed installation. The primary mounting frame defines an open interior to accommodate a fixture and includes a border flange along the outer edge of the open interior. A ratcheting fastener is rotationally coupled to the primary mounting frame to manually secure the mounting assembly in a ceiling or wall cavity. The ratcheting fastener is tightened by manually depressing it toward the border flange to secure the primary mounting frame between opposite surfaces of a mounting substrate. A retaining frame is coupled to the primary frame at an opposite end than the border flange to retain the ratcheting fastener between the primary mounting frame and the retaining frame. 
   According to one embodiment of the invention, the ratcheting fastener includes a ratchet post having a first longitudinal portion that has a plurality of substantially parallel teeth and a second longitudinal portion that is substantially smooth. The ratcheting fastener also includes a retainer having a sleeve defining a passage through which the ratchet post passes and one or more fingers flexibly protruding into the passage through which the ratchet post passes. The one or more fingers engage the substantially parallel teeth on the first longitudinal portion of the ratchet post when the ratchet post is in a first position, and slides over the substantially smooth portion on the second longitudinal portion of the ratchet post when the ratchet post is in a second position. The ratcheting fastener is released by rotating the retainer to disengage the one or more fingers from the teeth on the first longitudinal portion of the ratchet post, manually rotating the ratcheting fastener and sliding it away from the border flange to release the primary mounting frame. The ratcheting fastener is released by rotating the ratchet post to disengage the teeth on the first longitudinal portion from the one or more fingers on the retainer. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  illustrates an exploded side-view of a frame assembly fastening system according to one embodiment of the invention. 
       FIG. 2  illustrates a cross-sectional view of a frame assembly fastening system according to one embodiment of the invention. 
       FIG. 3  illustrates how a frame assembly maybe inserted and secured in a wall or ceiling opening according to one embodiment of the invention. 
       FIG. 4  illustrates a ratchet post according to one implementation of an embodiment of the invention. 
       FIGS. 5-7  illustrate various views of the dog ratchet fastener in a disengaged position according to one embodiment of the invention. 
       FIGS. 8-10  illustrate various views of the dog ratchet fastener in a secured position according to one embodiment of the invention. 
       FIGS. 11-12  illustrate the rotation of the ratcheting retainer from a first position to a second position according to one embodiment of the invention. 
       FIGS. 13-15  illustrate how a ratcheting retainer is slid to secure a frame assembly within a wall or ceiling cavity according to one embodiment of the invention. 
       FIGS. 16-18  illustrate how an installed frame assembly may be disengaged from a wall or ceiling cavity according to one embodiment of the invention. 
       FIG. 19  illustrates another aspect of the invention in which a secondary tightening means further secures the frame assembly to the wall or ceiling. 
       FIG. 20  is a diagram illustrating a method of mounting and securing a frame assembly within a wall or ceiling cavity according to one implementation of the invention. 
       FIG. 21  is a diagram illustrating a method of removing a frame assembly from within a wall or ceiling cavity according to one implementation of the invention. 
       FIG. 22  illustrates how a speaker housing may be mounted within an installed frame assembly according to one embodiment of the invention. 
   

   DETAILED DESCRIPTION 
   In the following description numerous specific details are set forth in order to provide a thorough understanding of the invention. However, one skilled in the art would recognize that the invention may be practiced without these specific details. In other instances, well known methods, procedures, and/or components have not been described in detail so as not to unnecessarily obscure aspects of the invention. 
   In the following description, certain terminology is used to describe certain features of one or more embodiments of the invention. For instance, “fastener” and “retainer” are interchangeably used to refer to any type of securing mechanism. The term “speaker” is used to refer to any type of sound-generating device such as audio electronic equipment, loudspeakers, audio speakers, woofers, subwoofers, audio mixers, tweeters, and acoustic transducers. The term “manually” refers to a motion or task performed by hand and without the aid of a tool. 
   One aspect of the invention provides a frame assembly for mounting fixtures within a recess in a wall or ceiling and can be installed with minimal time and effort. 
   Another aspect of the invention provides a fastener that can be manually installed and secured without the use of tools. 
     FIG. 1  illustrates an exploded view of a frame assembly fastening system according to one embodiment of the invention. This frame assembly and fastening system  100  does not require the use of hand-tools or power-tools for its installation, aside from a saw to cut the receiving hole or recess in the wall or ceiling. 
   The frame assembly  100  includes a primary frame  102  and a retaining frame  104 . According to one implementation, the primary frame assembly  102  is substantially circular and defines a cavity or opening  106  through which a speaker or other components may be mounted. The primary frame assembly  102  may include a border flange  108  which may serve as an external trim once the frame assembly  100  is mounted within a ceiling or wall recess. The primary frame  102  also includes a plurality of posts  110  on which the retaining frame  104  may be coupled by a pressure fit or one or more fasteners  112 . 
   The frame assembly may also include a tool-less fastening system which includes a ratcheting retainer or fastener  114 , a ratchet post  116 , a latch  118 , and a latch receiver  120 . The ratcheting retainer  114  includes a retaining arm  122 , a sleeve  124 , and an adjusting arm  126 . The sleeve  124  permits the ratchet post  116  to pass through the ratcheting retainer  114 . One or more pins or wedges  128  serve to secure a threaded portion of the ratchet post  116  as discussed in more detail below. The latch  118  is movably coupled to a receiving end  130  of the ratchet post  116 . When installed, the opposite end of the latch  118  is secured by the latch receiver  120 . When the frame assembly  100  is constructed, the ratchet post  116  passes through the sleeve  124  of the ratcheting retainer  114 , with a first end  132  of the ratchet post  116  fitting into a cavity in the primary frame  102  and a second end  130  fitting into a cavity in the retaining frame  104 . The retaining frame  104  is coupled to one or more posts  110  to secure the tool-less fastening components  114 ,  116 ,  118  between the primary frame  102  and retaining frame  104 . 
     FIG. 2  illustrates a cross-sectional view of a frame assembly fastening system according to one embodiment of the invention. The opening or cavity  106  through which a speaker or other components may be mounted is illustrated. Additionally, the primary frame  102  includes a plurality of flexible fingers  202  that help to align and secure a fixture housing  204 , e.g., speaker, fan, light, etc., that may be inserted into the opening  106 . The first end  132  of the ratchet post  116  ( FIG. 1 ) is inserted into a cavity  136  in the primary frame  102 . 
     FIG. 3  illustrates another cross-sectional view of how a frame assembly  100  maybe inserted into a wall or ceiling cavity according to one embodiment of the invention. In one implementation, a hole is cut into the ceiling or wall sheetrock  304 . The hole is large enough so that the frame assembly  100  fits through it but small enough so that the border flange  108  is capable of covering gaps between the frame assembly  100  and the front surface  304  of the wall or ceiling  302 . 
   The frame assembly  100  is inserted into the opening or recess with the ratcheting retainers  114  in a retracted position that permits the unobstructed insertion of the frame assembly  100  into the wall or ceiling opening. Once the frame assembly  100  is inserted in place, the installer can reach through the center opening  106  to manually rotate the ratcheting fastener  114  and slide it toward the border flange  108 . This causes the retaining arm  122  to press against the back surface of the sheetrock or drywall, in the wall or ceiling, and secure the frame assembly  102  in place. A ratcheting mechanism, discussed below, maintains the ratcheting fastener  114  in place. 
     FIG. 4  illustrates a ratchet post  116  according to one implementation of an embodiment of the invention. The ratchet post  116  includes an opening  130  into which one end of the latch  118  is inserted. The ratchet post  116  includes a first section of teeth or threads  402  along a first longitudinal portion of the post  116  and a substantially bare or smooth surface along a second longitudinal portion  404  of the post  116 . In one implementation of the invention, the ratchet post  116  may have substantially symmetrical threaded sections  402  and symmetrical bare sections  404 . When the frame assembly  100  is assembled, the first end  132  of the ratchet post  116  is inserted into a cavity in the primary frame  102 . 
     FIGS. 5-7  illustrate various views of the dog ratchet fastener in an disengaged position according to one embodiment of the invention.  FIG. 5  illustrates a cross section of the ratcheting retainer  114  with the ratchet post  116  inserted through the sleeve  124 . As illustrated in  FIG. 4 , the ratchet post  116  has a substantially smooth surface along the second longitudinal portion  404  that is inserted within the ratcheting retainer  114 . The ratcheting retainer  114  also includes one or more retaining spring fingers  128 . 
     FIGS. 5-7  illustrate that when the ratcheting retainer  114  is in a first position, the one or more fingers  128  rest against the substantially smooth second longitudinal portion  404  of the post  116  so that the ratcheting retainer  114  can move up or down along the ratchet post  116  without substantial restriction from the spring fingers  128 . In this first position, the spring fingers  128  slide against the substantially smooth second longitudinal portion  404 . 
     FIGS. 8-10  illustrate various views of the ratchet fastener  114  in an engaged position according to one embodiment of the invention. When the frame assembly  100  is inserted into a wall or ceiling opening and secured, the ratcheting retainer  114  is rotated so that the one or more pins or fingers  128  flexibly engage the teeth along the first longitudinal portion  402  of the ratchet post  116 . When the ratcheting fastener  114  is slid toward the border flange  108 , the orientation of the teeth along the first longitudinal portion  402  (illustrated in  FIG. 9 ) permits pins  128  and the ratcheting fastener  114  to slide down the post  116 , toward the first end  132 , but not in the opposite direction. That is, the ratchet post  116  features a ratcheted section  402  (first longitudinal portion) with teeth inclined in one direction (as shown in  FIG. 9 ) such that the retaining fastener  114  moves in only one direction (i.e., toward post end  132 ). This causes the frame assembly  100  to be secured by the border flange  108 , which presses against a first surface of the sheetrock, and the ratcheting fastener  114 , which presses against an opposite second surface of the sheetrock or drywall. 
     FIGS. 11-12  illustrate the rotation of the ratcheting retainer  114  from a first position to a second position according to one embodiment of the invention. In the first position, illustrated in  FIG. 11 , the ratcheting retainer  114  does not obstruct the insertion of the frame assembly  100  into an opening in the wall or ceiling. In this first position, the ratcheting retainer  114  is in the disengaged position relative to the ratchet post  116 , as shown in  FIGS. 5-7 . In such implementation, the ratchet post  116  and latch  118  are positioned and secured such that the pins or fingers  128  rest along the second longitudinal portion  404  of the post  116  (as shown in  FIG. 5-6 ), which is substantially smooth and without teeth. 
   Once inside the opening, an installer may rotate the ratcheting retainer  114 , by reaching through the opening  106  and rotating the adjusting arm  126  to a second position, illustrated in  FIG. 13 . When the ratcheting retainer  114  is rotated for securing the frame assembly  100 , the pins or fingers  128  engage the teeth along the first longitudinal portion  402  of the post  116  (as shown in  FIG. 8-9 ). In the second position, the ratcheting retainer  114  is in an engaged position relative to the ratchet post  116 , as illustrated in  FIGS. 8-10 , where the ratchet retainer pins or fingers  128  are engaged with the ratchet post teeth  402 . 
   From the second position illustrated in  FIG. 13 , the ratcheting retainer  114  maybe be pushed toward the border flange  108  to secure the frame assembly  100  against the sheetrock or board defining the mount opening as illustrated in  FIG. 14 . 
     FIG. 15  illustrates an installed frame assembly  100  according to one implementation of the invention, four rotating, finger actuated, ratcheting fasteners  114  are rotated approximately ninety (90) degrees around the central axis of their corresponding ratcheting retainer  114  passing through sleeve  124  and then slid up along the ratchet post  116  to secure the frame assembly  100  in place against a sheetrock or board  1502  sandwiched between the ratcheting retainer  114  and the boarder flange  108 . 
     FIGS. 16-18  illustrate how an installed frame assembly  100  may be disengaged from a wall or ceiling cavity according to one embodiment of the invention. A previously installed frame assembly  100  may be removed from the wall or ceiling cavity by reaching through the center opening  106 , disengaging the latch  118  from the latch receiver  120 , lifting the latch  118  (as shown in  FIG. 16 ), and rotating the latch  118  approximately ninety (90) degrees (as shown in  FIGS. 17 and 18 ). The rotation of the latch  118  also causes the ratchet post  116  to rotate with the latch  118  and relative to the ratchet retainer  114 . At the position illustrated in  FIG. 18 , the ratchet post  114  has been rotated so that it is disengaged from the ratchet retainer  114  as illustrated in  FIGS. 5-7 . In this position, the ratchet retainer pins or fingers  128  are disengaged with the ratchet post teeth  402  and rest against the smooth portion  404  of the ratchet post  116 . The ratchet retainer  114  may then be pulled down the ratchet post  116 , away from the border flange  108  to disengage the frame assembly  100 . This facilitates the removal of the frame assembly  100  from the wall or ceiling without damaging the ratchet fastener  114 , ratchet pins  128 , or the ratchet post teeth  402 . The ratchet retainer  114  can thus be retracted (i.e., slide towards the second end  130  of post  116 ) to release the frame assembly  100 . 
   Once the ratchet retainer pins  128  are disengaged from the post teeth  402 , the ratchet retainer  114  is retracted toward the second end  130  of the ratchet post  116 . The ratcheting retainer  114  may then be rotated, approximately ninety (90) degrees, to move the retaining arm  122  out of the way (to the position illustrated in  FIG. 11 ) and permit removal of the frame assembly  100 . 
     FIG. 19  illustrates another aspect of the invention in which a secondary tightening means further secures the frame assembly  100  to the wall or ceiling. In some instances, because of the spacing of the ratchet post teeth  402 , some play may be present when the ratcheting fastener  114  is in the secured position against the second surface  1902  of the wall or ceiling  1904 . Some small additional tightening may be necessary to fully secure the frame assembly  100  to the wall or ceiling  1904 . In one embodiment of the invention the latch  118  can be pushed into the latch receiver  120  to cause the ratchet post  116  to be pressed slightly toward the primary frame  102 . The latch  118  includes a lever point  1908 , which presses against the retainer frame  104  to cause the first end  1906  of the latch  118  to push on the second end  130  of the ratchet post  116 . This causes the ratchet post  116  to move towards the primary frame  102 , thus overcoming the any variation presented by the pitch (or spacing) of the ratchet post teeth  402 . The second end  1910  of the latch  118  is then secured against the receiving latch  120 . The receiving latch  120  includes one or more stops that help retain the second end  1910  of the latch  118 . The latch  118  may be released from the receiving latch  120  by flexing the receiving latch  120  away from the latch  118 . 
     FIG. 20  is a diagram illustrating a method of mounting and securing a frame assembly within a wall or ceiling cavity according to one implementation of the invention. Once an opening large enough to receive the frame assembly is made in the ceiling or wall, the frame assembly is inserted in the opening  2002 . The installer may reach through the center of the frame assembly to rotate the ratcheting fastener  2004 . The ratcheting fastener is then slid down to secure the frame assembly  2006 . If necessary, the lever coupled to the second end of the post may lifted to tighten the ratcheting fastener bit more  2008 . 
     FIG. 21  is a diagram illustrating a method of removing a frame assembly from within a wall or ceiling cavity according to one implementation of the invention. The latch is released from the latch receiver  2102  to permit rotating the latch and post and thus disengage the ratchet fastener  2104 . The ratcheting fastener is then slid to release the frame assembly  2106 . The ratcheting fastener may then be rotated to a retracted or unobstructed position  2108  so that the frame assembly may be removed from the opening  2110 . 
     FIG. 22  illustrates how a speaker housing may be mounted within a mounting frame assembly according to one embodiment of the invention. The speaker housing  204  is configured to fit snug through the frame assembly opening  106 . The upper retaining fingers  202  flex back as the speaker housing  204  reaches that point. Retainers  2202  and  1004  in the speaker housing  204  may be rotated to slide over the fingers  202  and secure the speaker housing  204  in place. 
   According to one embodiment of the invention, the speaker housing  204  includes a baffle and manually engaging fasteners that couple the speaker housing  204  to the mounting frame assembly  102 . Even when the fasteners  2202  secure the speaker housing  204  to the mounting frame assembly  102 , the speaker housing  204  can freely rotate three hundred and sixty degrees as fastener footings  1004  slide over the retaining fingers  202 . 
   Various embodiments of the invention may be implemented using parts, fasteners, frames, baffles, etc., constructed from one or more materials, or combination of material, including plastic, metal, polymers, and/or any other material. 
   While certain exemplary embodiments have been described and shown in the accompanying drawings, it is to be understood that such embodiments are merely illustrative of and not restrictive on the broad invention, and that this invention not be limited to the specific constructions and arrangements shown and described, since various other modifications are possible. Those skilled, in the art will appreciate that various adaptations and modifications of the just described embodiments can be configured without departing from the scope and spirit of the invention. Therefore, it is to be understood that, within the scope of the appended claims, the invention may be practiced other than as specifically described herein.