Patent Publication Number: US-7587059-B2

Title: Snap-in and lock baffle

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. 10/871,112 filed on Jun. 18, 2004 by inventor Doug S. Wright, titled “Tool-Less Frame Fastening System”, 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 a baffle assembly. More particularly, at least one embodiment of the invention relates to a device, system, and method for fastening an integrated speaker and baffle assembly into a recessed mounting assembly. 
   DESCRIPTION OF RELATED ART 
   Various types of apparatus, such as speakers, vents, and exhaust fans, are often mounted within a wall or ceiling cavity or recess. A frame assembly is commonly mounted within a wall or ceiling cavity to retain these devices. Various types of baffle frames and fasteners are used for the purpose of securing a baffle, cover, shield, or grate over the device to hide it from view. 
   Many conventional devices, such as speakers, may be mounted to a frame assembly within a wall or ceiling recess. A baffle is then fitted, either by pressure or by a fastener, to cover the speaker. This process is often cumbersome, time consuming and laborious in many cases since it requires that the installer use tools to secure the speaker to the frame assembly and then install a separate baffle to cover the fasteners and speakers. For example, when installing a recessed speaker within a ceiling cavity the installer would have to hold the speaker frame in place with one hand while trying to turn a screw to secure the speaker to a previously installed mounting frame. Then a cover or baffle is used to cover the speaker. Moreover, conventional baffles and speakers are not easy to remove and/or replace when maintenance may be required. 
   Consequently, conventional baffle and speaker securing systems 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 provides a manually mounted a speaker baffle assembly. The baffle assembly includes a baffle frame defining an opening to receive a fixture (e.g., speaker). The baffle frame has an exposed first surface visible to users. A fastener is rotationally coupled to the baffle frame and extends from the exposed first surface to secure the baffle assembly to a recessed mounting frame. The fastener can be manually rotated from a disengaged position to an engaged position in less than one full turn. 
   The baffle assembly also includes a retaining ring coupled to the baffle frame, the retaining ring having a plurality of aligning posts that serve to align the baffle assembly as it is inserted into a recessed mounting frame. The retaining ring includes an angled sidewall along the circumference of the opening defined by the baffle frame. 
   The baffle assembly may also include an inner mounting assembly to couple to a fixture (e.g. speaker), the inner mounting assembly having an angled sidewall to slide against the angled sidewall of the retaining ring and provide a desired angle for the fixture. 
   According to one embodiment of the invention, the fastener includes a tensioning pin, a knob coupled to a first end of the tensioning pin on the exposed first surface, a tensioning spring along the tensioning pin, and a securing foot coupled to a second end of the tensioning pin. Rotating the knob causes the tensioning pin and securing foot to rotate and engage one or more spring fingers in the recessed mounting frame to secure the baffle assembly to the recessed mounting frame. 
   The baffle frame includes at least one passage through which a fastener extends from the exposed first surface to an opposite end, the passage including a tensioning ramp edge along the circumference of the passage, a knob on the fastener rotates on the tensioning ramp edge to secure the baffle assembly. The fastener may be manually rotated from a disengaged position to an engaged position in approximately one half turn. The fastener includes a visible finger actuator, the finger actuator to align with a rib on the exposed first surface when the fastener is in the engaged position. The baffle assembly remains free to rotate three hundred and sixty degrees even when the fastener secures the baffle assembly to the recessed mounting frame. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  illustrates an exploded side-view of a baffle assembly fastening system and mounting frame assembly according to one embodiment of the invention. 
       FIG. 2  illustrates one implementation of the mounting frame assembly, including a tool-less fastening system to secure the mounting frame assembly within the ceiling or wall recess. 
       FIG. 3  illustrates a cross-sectional view of the mounting frame assembly and baffle assembly fastening system illustrated in  FIG. 1 . 
       FIG. 4  illustrates a cross-sectional exploded view of a tool-less fastening system that may be employed to secure the baffle  100  to a mounting frame assembly according to one embodiment of the invention 
       FIGS. 5 and 6  illustrate two positions of the tool-less fastening system that may be employed to secure a baffle to a mounting frame assembly according to one embodiment of the invention. 
       FIG. 7  illustrates an underside view of the tensioning pin in the secured position with the foot over the spring fingers according to one implementation of the invention. 
       FIG. 8  illustrates a tensioning pin used to secure a baffle to a mounting frame assembly according to one embodiment of the invention. 
       FIG. 9  illustrates a baffle assembly, coupled to a mounting frame assembly and mounted on a surface according to one embodiment of the invention. 
       FIG. 10  illustrates a cross sectional view of the baffle assembly and mounting frame assembly illustrated in  FIG. 9 . 
   

   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. 
   One aspect of the invention provides a baffle assembly fastening system and mounting frame assembly that can be installed and secured without the use of tools. 
     FIG. 1  illustrates an exploded side-view of a baffle assembly fastening system  100  and mounting frame assembly  102  according to one embodiment of the invention. The baffle assembly  100  and mounting frame assembly  102  do 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. This mounting frame assembly  102  and baffle assembly  100  system incorporates an alignment free, snap-in retention system that allows free, three-hundred and sixty degrees (360°), rotation after insertion, is lockable to eliminate buzz and rattle and does not require tools to fully affix. 
   The mounting frame assembly  102  may be secured within a recess in a wall or ceiling and then the baffle assembly  100  may be secured to the mounting frame assembly  102 . For this purpose, baffle assembly may include a tool-less fastening system having a rotating tensioning pin  108  and a locking knob  110 . 
   According to one implementation of the invention, the mounting frame assembly  102  is substantially circular and defines a cavity or opening  104  through which a speaker or other components may be mounted. The mounting frame assembly  102  may include a border flange  106  which may serve as an external trim once the mounting frame assembly  102  is mounted within a ceiling or wall recess in a number of different ways. 
     FIG. 2  illustrates one implementation of the mounting frame assembly  102 , including a tool-less fastening system to secure the mounting frame assembly  102  within the ceiling or wall recess. The tool-less fastening system includes a ratcheting retainer or fastener  214 , a ratchet post  216 , a latch  218 , and a latch receiver  220 . The ratcheting retainer  214  includes a retaining arm  222 , a sleeve  224 , and an adjusting arm  226 . The sleeve  224  permits the ratchet post  216  to pass through the ratcheting retainer  214 . One or more pins or wedges  228  serve to secure a threaded portion of the ratchet post  216  as discussed in more detail below. The latch  218  is movably coupled to a receiving end  230  of the ratchet post  216 . When installed, the opposite end of the latch  218  is secured by the latch receiver  220 . When the frame assembly  102  is constructed, the ratchet post  216  passes through the sleeve  224  of the ratcheting retainer  214 , with a first end  232  of the ratchet post  116  fitting into a cavity in the mounting frame assembly  102  and a second end  230  fitting into a cavity in the retaining frame  204 . The retaining frame  204  is coupled to one or more posts  210  to secure the tool-less fastening components  214 ,  216 ,  218  between the mounting frame assembly  102  and retaining frame  204 . 
   According to one implementation of the invention, the ratchet post  216  includes an opening  230  into which one end of the latch  218  is inserted. The ratchet post  216  includes a first section of teeth or threads along a first longitudinal portion of the post  216  and a substantially bare or smooth surface along a second longitudinal portion of the post  216 . When the mounting frame assembly  102  is assembled, the first end  232  of the ratchet post  216  is inserted into a cavity in the mounting frame assembly  102 . 
   The mounting frame assembly  102  is inserted into the wall or ceiling recess with the ratcheting retainers  214  in a retracted position that permits the unobstructed insertion of the mounting frame assembly  102  into the wall or ceiling recess. Once the mounting frame assembly  102  is inserted in place, the installer can reach through the center opening  104  to rotate the ratcheting fastener  214  and slide it toward the border flange  106 . This causes the retaining arm  222  to press against the back surface of the sheetrock or drywall, in the wall or ceiling, and secure the frame assembly  102  in place. That is, the mounting frame assembly  102  is secured by the border flange  106 , which presses against a first surface of the sheetrock, and the ratcheting fastener  214 , which presses against an opposite second surface of the sheetrock or drywall. 
   In one implementation of the invention the ratcheting retainer  214  is in a first position so that it does not obstruct the insertion of the mounting frame assembly  102  into the opening in the wall or ceiling. Once inside the recess, an installer may rotate the ratcheting retainer  214 , by reaching through the opening  104 , rotating the adjusting arm to a second position, and pressing the adjusting arm toward the border flange  106  to secure the ratcheting retainer against the second surface of the sheetrock. In such implementation, the ratchet post and latch  218  are positioned and secured such that the pins or fingers  228  rest along the second longitudinal portion of the post  216 , which is substantially smooth and without teeth. When the ratcheting retainer  214  is rotated for securing the mounting frame assembly  102 , the pins or fingers  128  engage the teeth along the first longitudinal portion of the post  116 . 
     FIG. 3  illustrates a cut-out view of the mounting frame assembly  102  and baffle assembly fastening system  100  illustrated in  FIG. 1 . The baffle assembly  100  is inserted into the mounting frame assembly  102  with a simple, linear motion that does not require any pre-alignment. The baffle  100  includes a retaining ring  302 , fastened to the baffle  100 , and having a plurality of aligning posts  306  that serve to align the baffle assembly  100  as it is inserted within opening  104  in the mounting frame assembly  102 . The mounting frame assembly  102  includes a plurality of spring arms  308  that are bent toward the opening  104 . The spring arms  308  may flex outwardly as the aligning posts  306  are inserted. However, those spring arms  308  that are not in contact with the aligning posts  306  remain bent towards the opening  104 . 
   After the baffle  100  has been inserted into the opening  104  beyond a given point, the baffle  100  is retained in place by the engagement of one or more fasteners. 
     FIG. 4  illustrates a cross-sectional exploded view of a tool-less fastening system that may be employed to secure the baffle  100  to a mounting frame assembly according to one embodiment of the invention. The tool-less fastening system includes a tensioning pin  108  that passes through a tensioning spring  418 , then passes through an opening  404  in the baffle  110  and inserts into a cavity  401  in a knob  110 . 
     FIGS. 5 and 6  illustrate two positions of the tool-less fastening system that may be employed to secure a baffle  100  to a mounting frame assembly  102  according to one embodiment of the invention.  FIG. 5  illustrates a cross-sectional view of a fastener  108  and  110  at a first position when the baffle  100  is disengaged from (not secured to) the mounting frame assembly  102 .  FIG. 6  illustrates a second position of the fasteners  108  and  110  when the baffle  100  is secured to the mounting frame assembly  102 . 
   The fastening system includes one or more tensioning pins  108  coupled to knobs  110 . As illustrated in  FIG. 6 , the knob  110  is rotated to cause a foot  402  to rotate and push past the spring fingers  308 . Once past the spring fingers  308 , as illustrated in  FIG. 6 , the tensioning pin offset foot  402  is prevented from disengaging from the mounting frame assembly  102  by the position and spring tension of the spring fingers  308 .  FIG. 7  illustrates an underside view of the tensioning pin  108  in the secured position with the foot  402  over the spring fingers  308  to secure the baffle  100  to the frame assembly  102  according to one implementation of the invention. 
   Even when the baffle  100  is engaged with the mounting frame assembly  102 , as illustrated in  FIG. 6 , the baffle  100  remains free to rotate inside the mounting frame assembly  102 . That is, when in the engaged position, the securing foot  402  may slide along the upper edge of the spring arms  308  as the baffle is rotated. 
   In one implementation of the invention, the fastening system is assembled as part of the baffle  100 . A first end  403  of the tensioning pin  108  passes through a passage  404  in the baffle  100  and is coupled to a receiving cavity  401  in the knob  110 . 
   The fastening system may further include a feature that lifts the tensioning pin  108  in such a way that it locks the rotating baffle  100  to the mounting frame assembly  102 . In one implementation of the invention, this is accomplished through the engagement of the knob&#39;s ramp pin  406  with the rotating baffle&#39;s tension ramp  408  as the knob  110  is rotated clockwise ninety degrees (90°) from its initial preset position (unlocked,  FIG. 5 ) into its full lock position ( FIG. 6 ). In one embodiment of the invention, the full lock position is indicated to an installer when the knob finger actuator  410  is aligned with the rotating baffle&#39;s knob alignment rib  412 . The unlocked, initial preset position is approximately ninety degrees (90°) counter-clockwise from the knob&#39;s  110  full lock position. 
   The tensioning pin  108  is rotationally secured to the rotating baffle  100  by retaining pins  414  found on the inside of the knob  110 . These retaining pins  414  engage the tensioning pin  108  via matching slots  420  on the post end  403  of the tensioning pin  108 . After sliding down the engagement slot  420 , illustrated in  FIG. 8 , the knob&#39;s retaining pins  414  are free to rotate clockwise past the disassembly stop  422  into the knob retention slot  416  wherein it is free to rotate approximately ninety degrees (90°). 
     FIG. 8  illustrates a tensioning pin  108  used to secure a baffle  100  to a mounting frame assembly  102  according to one embodiment of the invention. A tensioning spring  418  is mounted around the tensioning pin collar  424  ( FIG. 8 ) to press against the baffle  100  and prevent the knob&#39;s retaining pins  414  from slipping past the engagement slot and disengaging the knob  110  from the tensioning pin  108 . 
   As illustrated in  FIGS. 5 and 7 , rotation-limiting stops  426  are part of the inner rotating baffle  100  according to one aspect of an embodiment of the invention. The tensioning pin  108  includes a rotation-limiting arm  428  that restrict the pin&#39;s rotation when the arm  428  comes into contact with the rotation-limiting stops  426 . The tensioning pin&#39;s  108  rotation may be limited by stops  426  molded on the retaining ring  302  along the inner perimeter of the baffle  100  and the outer perimeter of the baffle adjacent to the spring fingers  308 . These stops  426  may be positioned to allow the tensioning pin  108  to rotate approximately ninety degrees (90°) from the preset/disengaged position to the full lock/engaged position. When the knob  110  is rotated counter-clockwise past the preset/disengaged position, the knob&#39;s retaining pins  414  engages the tensioning pin&#39;s disassembly stop  422  causing the tensioning pin  108  to rotate and, thereby, disengaging the tensioning pin&#39;s foot  402  from the mounting frame&#39;s spring fingers  308 . Rotating the knob  110  clockwise ninety degrees (90°), from its fully disengaged position to the fully engaged position, causes the tensioning pin  108  to rotate, returning it to the preset position. 
   The baffle assembly  100  may be inserted into the mounting frame assembly  102  or removed from the mounting frame assembly  102  when the tensioning pins  108  are in the disengaged position ( FIG. 5 ) (i.e., the pin&#39;s foot  402  is disengaged from the spring fingers  308 ). Once the baffle assembly  100  is inserted into the mounting frame assembly  102 , the tool-less fastening system may secure the baffle assembly to the mounting frame assembly  102 . To engage the pin&#39;s foot  402  with the spring fingers  308 , the knob&#39;s ramp pin  406  travels along the baffle&#39;s tensioning ramp  408  as the knob  110  is rotated to the secured position where the pin  406  engages a notch  430 .  FIGS. 6 and 7  illustrate the knob  110  and tensioning pin  108  in the secured or engaged position. Disengaging the tensioning pin  108  from the spring fingers  308  is accomplished by pulling the knob away from the pin to release the ramp pin  406  from the notch  430  and turning the knob  110  counter-clockwise. 
     FIG. 9  illustrates a baffle assembly  100 , coupled to a mounting frame assembly  102  and mounted on a surface  902  according to one embodiment of the invention.  FIG. 10  illustrates a cross sectional view of the baffle assembly  100  and mounting frame assembly  102  illustrated in  FIG. 9 . An inner fixture mounting assembly  906  serves to support a fixture  908 , such as a speaker. The inner fixture mounting assembly  906  may be rotationally mounted within the baffle assembly  100 . The inner fixture mounting assembly  906  may be rotated three hundred sixty degrees (360°) and angled to provide a desired position for the fixture  908  mounted therein. 
   According to one implementation, a retaining ring  302  ( FIGS. 1 and 2 ), which is part of the baffle assembly  100 , includes an angled wall  304  along its inner circumference. The inner mounting assembly  906  includes angled rim that slides against the angled wall edge  304  of the baffle assembly  100  to provide the desired angle for the fixture  908 , such as a speaker, that may be mounted in the inner mounting assembly. That is, the angled rim turns against a ridge on the angled wall  304 . Thus, a desired angle, within a certain range of angles, may be achieved by rotating the inner mounting assembly  906 . 
   The range of fixture angles that can be achieved by this system will depend on the angles provided by the angled rim and angled ridge. Additionally, as previously discussed, the baffle assembly  100  can also be rotated three hundred sixty degrees, consequently turning the fixture  908  attached to the inner mounting assembly  906 , to achieve the desired angle and direction. 
   According to one implementation of the invention, an extendable post assembly  910  may be part of the fixture  908 . The extendable post assembly  910  may include a ball and socket support  912  on which a second fixture  914 , such as a woofer, may be mounted. 
   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.