Patent Publication Number: US-10785884-B2

Title: In-wall amplifier and controller housing and related methods

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of U.S. Provisional Patent Application Ser. No. 62/616,731, filed on Jan. 12, 2018, the contents of which are herein incorporated by reference in their entirety. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to in-wall distributed audio systems, and more particularly, in-wall distributed audio systems utilizing wireless communication devices. 
     BACKGROUND OF THE INVENTION 
     For many home and business owners, an in-wall distributed audio system, that can supply amplified audio to built-in speakers in multiple rooms, is a highly desirable, high-end option. Such a system typically requires multiple specialized components and, in practice, must be installed in a relatively large number of rooms. 
     The recent development of small, networked wireless communication devices like the Amazon Echo Dot (a trademark of Amazon Technologies, Inc.) or the Google Home Mini (a trademark of Google LLC), allow a sort of distributed audio network—controlled with convenient voice recognition-based controls—to be flexibly introduced simply by adding additional devices to the same wireless network. 
     However, the volume and/or sound quality available from such devices is often inadequate for the audio preferences of users. Additionally, while relatively small in size, they still lack the extremely low profile, custom look of in-wall systems. Consequently, further improvements are possible. 
     SUMMARY OF THE INVENTION 
     In view of the foregoing, it is an object of the present invention to provide an improved in-wall amplifier assembly. According to an embodiment of the present invention an in-wall amplifier assembly comprises connected first and second housings, a wireless communication device and amplifier in the first housing, and an alternating current/direct current (AC/DC) adapter arranged in the second housing. 
     The first housing at least partially defines a first housing interior volume and includes a first housing sidewall extending between axial inner and outer first housing sidewall ends. The second housing is connected to the first housing and defines a second housing interior volume and includes a second housing sidewall extending between axial inner and outer second housing sidewall ends, a second housing axial inner and outer endwalls extending across the axial inner second housing sidewall ends, respectively. 
     A flange is connected to at least one of the first and second housing axial outer ends and extends radially beyond a periphery thereof so as to seat against a wall around a periphery of a wall opening with the first and second housings extending axially thereinto. 
     The wireless communication device is arranged within the first housing interior volume, and is DC powered and configured to generate a wireless communication device audio output. The amplifier is arranged within the first housing interior volume, the amplifier being DC powered and is configured to generate an amplified audio output from at least a first amplifier audio input, the first amplifier audio input being connected to the wireless communication device audio output. An audio output connector is located in the first housing connected to the amplified audio output and is configured to connect to at least one external speaker. 
     An alternating current (AC) power connection is arranged in the second housing and configured to connect to an AC power source. An AC/DC adapter is also arranged in the second housing, and has an adapter input connected to the AC power connection and an adapter output supplying DC power to the wireless communication device and the amplifier in the first housing. 
     According to another embodiment of the present invention, an in-wall amplifier assembly for a wireless communication device comprises a first housing with an amplifier arranged therein. 
     The first housing at least partially defines a first housing interior volume and includes a first housing sidewall extending between axial inner and outer first housing sidewall ends, and a faceplate at least partially covering the first housing axial outer end. A receptacle opening is defined in the faceplate with a receptacle sidewall extending axially into the first housing interior volume from the receptacle opening. The receptacle sidewall at least partially defines a receptacle volume dimensioned to accommodate the wireless communication device therein. 
     A wall plate is releasably connected to the first housing overlying the faceplate, a receptacle access opening is defined in the wall plate aligned with the receptacle opening, and a radial dimension of the receptacle opening is smaller than a corresponding radial dimension of the receptacle opening, such that the wall plate is able to releasably retain the wireless communication device within the receptacle volume. 
     Wireless communication device audio output and power connectors extend into the receptacle volume and are configured, respectively, for releasable connection to wireless communication device audio output and power input. 
     The amplifier is arranged within the first housing interior volume and is configured to generate an amplified audio output from at least a first amplifier audio input. The first amplifier audio input is connected to the wireless communication device audio output connector. 
     An audio output connector is located in the first housing connected to the amplified audio output and is configured to connect to at least one external speaker. At least one power connection is connected to the amplifier and the wireless communication device power connector and is configured to connect to a power source. 
     According to a further embodiment of the present invention, an in-wall amplifier assembly for a wireless communication device comprises a first housing with a wireless communication device and an amplifier arranged therein. 
     The first housing at least partially defines a first housing interior volume and includes a first housing sidewall extending between axial inner and outer first housing sidewall ends. A flange is connected to the first housing axial outer end and extends radially beyond a periphery thereof so as to seat against a wall around a periphery of a wall opening with the first housing extending axially thereinto. 
     The wireless communication device is arranged within the first housing interior volume, the wireless communication device configured to generate a wireless communication device audio output. 
     An external audio input connector is located in the first housing, is connected to the second amplifier audio input, and is configured to connect to at least one external audio input. 
     The amplifier is arranged within the first housing interior volume, and is configured to selectively generate an amplified audio output from the first or second amplifier audio inputs. The first amplifier audio input is connected to the wireless communication device audio output, and the second amplifier audio input is connected to the external audio input connector. The amplifier includes control electronics configured to automatically switch the amplified audio output to the first amplifier audio input when the wireless communication device audio output is detected. 
     An audio output connector is located in the first housing connected to the amplified audio output and configured to connect to at least one external speaker. At least one power connection is connected to the amplifier and the wireless communication device power connector and is configured to connect to a power source. 
     These and other objects, aspects and advantages of the present invention will be better appreciated in view the drawings and following detailed description of preferred embodiments. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a partially exploded perspective view of an in-wall amplifier assembly, according to an embodiment of the present invention; 
         FIG. 2  is a schematic view of the in-wall amplifier assembly of  FIG. 1 ; 
         FIG. 3  is a perspective view of a first housing of the in-wall amplifier assembly of  FIG. 1 ; 
         FIG. 4  is a perspective view of the first housing of  FIG. 3 , with a wireless communication device removed; 
         FIG. 5  is a perspective view of the in-wall amplifier assembly of  FIG. 1 ; 
         FIG. 6  is a front view of the in-wall amplifier assembly of  FIG. 2 , with a wall plate shown adjacent thereto and alternate components shown in broken lines; 
         FIG. 7  is another perspective view of the in-wall amplifier assembly of  FIG. 1 ; and 
         FIG. 8  is a perspective view of a second housing of the in-wall amplifier assembly of  FIG. 1 . 
     
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     Referring to  FIGS. 1 and 2 , according to an embodiment of the present invention, and in-wall amplifier assembly  10  includes connected first and second housings  12 ,  14  dimensioned to insert through a wall opening  16 . An interior volume of the first housing  12  holds a wireless communication device  18  and an amplifier  20 . An interior volume of the second housing includes an alternating current (AC) to direct current (DC) adapter  22 . 
     As used herein, the “axial” direction is the direction in which the assembly  10  is inserted through the wall opening. With reference to the axial direction, “in” and “out” refer to positions that are, respectively, further into (or less far out of) the wall and less far into (or further out of) the wall. 
     The “radial” direction is any direction perpendicular to the axial direction; for instance, the width and height of the wall opening  16  are both radial dimensions. The reference to a component extending in the radial direction or having a radial extent does not necessarily imply that such a component is circular. 
     Referring to  FIGS. 3 and 4 , the first housing  12  has a first housing sidewall  24  extending between inner and outer sidewall ends  26 ,  30  which partially defines the interior volume of the first housing. The wireless communication device  18  and amplifier  20  are located within the first housing sidewall  24 . 
     A faceplate  32  extends across the axial outer end  30  of the sidewall  24 . A flange  34  is formed by a periphery of the sidewall  24  extending radially beyond the first housing sidewall  24 . The flange  34  seats against the wall  36  a periphery of the wall opening  16  (see  FIG. 1 ) with the in-wall amplifier assembly  10  fully inserted in the axial direction. 
     In the depicted embodiment, the wireless communication device  18  is a separate device removably accommodated in the first housing  12 —such as the depicted device  18  which can be acquired from Amazon Technologies, Inc., or functionally similar devices available from Google LLC, which entities are unrelated to the current applicant. However, the present invention also encompasses embodiments in which the wireless communication device  18  is implemented on circuitry permanently installed within the first housing  12 . 
     With the removable wireless communication device  18 , a receptacle opening  40  is defined in the faceplate  32  with a receptacle sidewall  42  extending axially into the interior volume of the first housing  12  from the opening  40 . A receptacle endwall  44  extends across the axial inner end of the receptacle sidewall  42 . The receptacle sidewall  42  and endwall  44  define a receptacle volume which closely accommodates the wireless communication device  18 . 
     Indexing marks  46  are formed on the endwall  44  to help identify a correct orientation for placement of the wireless communication device  18  within the receptacle volume. Proper orientation of the device  18  is also facilitated by the connection opening  50  defined in the receptacle sidewall  42 , as will be explained in greater detail below. 
     Referring to  FIGS. 5 and 6 , a wall plate  52  overlies the faceplate  32 . A receptacle access opening  54  is defined in the wall plate  52  which is aligned with the receptacle opening  40 . A radial dimension of the access opening  54  in the wall plate  52  is smaller than the corresponding radial dimension of the receptacle opening  40  (and of the wireless communication device  18 ). With the wall plate  52  in place, the smaller opening  54  ensures the wireless communication device  18  remains retained in the receptacle volume. 
     To allow wireless communication devices of different dimensions to be accommodated, the receptacle sidewall  42  can include a removable insert  56  around the periphery thereof. With the insert  56  in place, a smaller wireless communication device  18 A can be closely accommodated in a reduced receptacle volume. Conversely, with the insert  56  removed, the larger wireless communication device  18  can be accommodated. A connection opening  50 A aligned with the connection opening  50  is defined to extend through the corresponding portion of the insert  56 . 
     An alternate wall plate  52 A is also supplied with an alternate access opening  54 A defined therein that is smaller in radial dimension that the removable insert (and the smaller device  18 A). If the insert  56  is used, then the alternate wall plate  52 A is used and works just as the wall plate  52 , described above. With the insert  56  removed and the larger wireless communication device  18  in place, the wall plate  52  is used. 
     Referring again to  FIGS. 3 and 4 , to securely affix the in-wall amplifier assembly  10  inside the wall opening  16 , clamps  58  are provided on the first housing  12  that are operable after insertion via connections on the faceplate  32 . Deploying and tightening the clamps  58  ensures that the flange  34  remains firmly engaged with the wall  36  around the periphery of the wall opening  16  (see  FIG. 1 , where clamps  58  are rotated inward to allow insertion/removal). The clamps  58  can be loosened and disengaged if removal of the assembly  10  is desired. 
     In general, the wireless communication device  18  is configured to connect to a wireless network and, from data received therefrom, generate an audio output. Wireless communication devices equipped with additional functionality (e.g., microphones to recognize user spoken commands) can be used. With the removable device  18 , its audio output is releasably connected to an audio output connector  60  which extends through the connection opening  50  of the receptacle sidewall  42 . The output connector  60  connects the audio output of the wireless communication device to the amplifier  20 . 
     Power for the removable wireless communication device  18 , typically low voltage DC power, is supplied via a releasable power connector  62  also extending through the connection opening  50  of the receptacle sidewall  42 . The connection of the device  18  to the connectors  60 ,  62  further helps ensure the proper orientation within the receptacle volume. In the depicted embodiment, the audio output and power connectors  60 ,  62  are implemented as separate plugs. It will be appreciated that both connectors could also be implemented on a single plug. 
     Referring also to  FIG. 2 , the amplifier  20  is configured to receive wireless communication device  18  audio output as an audio input, amplify the audio input to generate an amplified audio output and supply the amplified audio output to an audio output connector  64  located on the first housing  12 . The audio output connector  64  is configured to connect to one or more external speakers  66 . 
     Advantageously, the amplifier  20  is able to receive at least two audio inputs, one from the wireless communication device  18  and the other from an external audio input connector  70  located on the first housing. The external audio input connector  70  allows the in-wall amplifier assembly  10  to also amplify audio signals from a non-networked audio source. For example, the stereo audio output from a television in the room where the in-wall amplifier assembly  10  is installed could be plugged into the connector  70 , allowing for amplified audio output via the external speakers  66 . 
     To control switching the amplified audio output between the different audio inputs, the amplifier  20  is preferably equipped with control electronics  72  which are operable to detect the wireless communication device  18  audio output and automatically switch the amplified audio output (and consequently the sound playing through the external speakers  66 ) to use the device  18  audio output as the active amplifier audio input. When the audio output from the device  18  is no longer detected, the amplified audio output will automatically switch back to the external audio input connector  70 . The control electronics  72  can be implemented via an analog or digital circuitry. Additionally, a user control allowing manual switching and/or allowing a user to select between automatic and manual switching could be employed. 
     As will be appreciated, an in-wall amplifier assembly according to embodiments of the present invention allows a built-in distributed audio system to be quickly and easily installed in a multi-room home, business or other structure by leveraging existing capabilities of wireless communication devices in a unique in-wall architecture. Additionally, as-in the depicted embodiment, an existing separate wireless communication device can simply be used to “plug-and-play” into the in-wall assembly, which further enables other devices in the particular room(s) to utilize the amplifier capabilities of the in-wall assembly. 
     In the depicted embodiment, the power for the wireless communication device  18  and amplifier  20  are supplied via the AC/DC adapter  22  located in the interior volume of the second housing  14 . Referring to  FIGS. 7 and 8 , the second housing  14  includes a sidewall  74  extending between axial inner and outer sidewall ends  76 ,  80 . The second housing  14  is connected at its axial outer end  80  to the first housing axial inner end  26 . The radial dimensions of the second housing sidewall  74  are no larger than those of the first housing sidewall  24 , ensuring both can be inserted through the wall opening  16  (see  FIG. 1 ). 
     The second housing  14  preferably completely encloses its interior volume except where electrical inputs and outputs penetrate. Referring also to  FIG. 2 , the inputs and outputs include a converter output  82  supplying low voltage DC power to the wireless communication device  18  and the amplifier  20 , as well as an AC power input received at an AC power connection  84 . Any suitable AC/DC adapter  22  can be used, with the unit typically comprising a transformer, a rectifier and one or more filters and regulators. 
     By structurally separating the higher voltage AC equipment from the lower voltage wireless communication device and amplifier, the first housing  12  can be made more lightweight and be more easily fabricated, with the attached second housing  14  still providing onboard AC/DC conversion. Alternately, the second housing  14  could be omitted and the wireless communication device  18  and the amplifier  20  could receive suitable DC power directly from one or more external power sources. 
     In use with only the first housing  12 , the overall size of the amplifier assembly  10  can be significantly reduced and can be accommodated within a wall opening having less depth in the axial direction. With smaller wireless communication devices, the assembly can even be dimensioned to fit within a standard double gang electrical box. In a plug-and-play configuration with a suitably dimensioned removable wireless communication device, it may be necessary to locate the wireless communication device radially eccentrically within the double gang box to ensure sufficient room exists to make the power and audio connections to the device within the box. 
     In general, the foregoing description is provided for exemplary and illustrative purposes; the present invention is not necessarily limited thereto. Rather, those skilled in the art will appreciate that additional modifications, as well as adaptations for particular circumstances, will fall within the scope of the invention as herein shown and described and of the claims appended hereto.