Patent Publication Number: US-7910827-B2

Title: Adapter plate assembly for outdoor installation of notification appliances

Description:
This application is a continuation of U.S. patent application Ser. No. 11/752,091, filed May 22, 2007 now U.S. Pat No. 7,683,255, which is currently allowed and is herein incorporated by reference in its entirety. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to an apparatus that allows outdoor weatherproof installation of notification appliances without having the conduit run on the outside of a building. More specifically, the present invention provides an adapter plate for outdoor installation of notification appliances. 
     2. Description of the Related Art 
     Currently, some buildings are required by building code to have notification appliances on the outside. Notification appliances may be, for example, any visual alarms, audio alarms, speakers and the like. Notification appliances may be placed on the outside of buildings where people may be walking around outdoors, for example, outdoor eating areas, outdoor shopping malls, and the like. 
     Unfortunately when notification appliances are currently placed on the outside of a building, they are normally connected to a large back box and conduit carrying wiring to the notification appliance. The back box and conduit on the exterior of a building is undesirable because one may spend a great deal of resources to construct an appealing building that will attract patrons or for personal enjoyment, but the back box and conduit may be big, bulky and unattractive when deployed on the exterior of the building. Moreover, the conduit may run many feet along the exterior of the building and further detract from the aesthetic appeal of the building. 
     SUMMARY OF THE INVENTION 
     The present invention generally discloses an adapter plate assembly for outdoor notification appliances. In one embodiment, the adapter plate assembly comprises a plate, a first gasket coupled to a front side of said plate and a second gasket coupled to a backside of said plate. The plate comprises a front side, a back side, at least one mounting member for receiving a back box and at least one mounting member for receiving a notification appliance. 
     In an alternate embodiment, a notification appliance assembly is disclosed. The notification appliance assembly comprises an adapter plate assembly, a notification appliance and a back box. The adapter plate assembly comprises a plate, a first gasket coupled to said front side of said plate and a second gasket coupled to said back side of said plate. The plate comprises, a front side, a back side, at least one mounting member for receiving a back box and at least one mounting member for receiving said notification appliance. The notification appliance may be similar in geometry and perimeter dimensions as said plate and coupled to said front side of said plate, wherein said first gasket forms a substantially weatherproof seal between said front side of said plate and said notification appliance. The back box may be installed flush with an exterior side of a wall and coupled to said back side of said plate, wherein said second gasket forms a substantially weatherproof seal between said back side of said plate and said exterior side of said wall. 
     In another embodiment, the present invention provides a method of installing a notification appliance comprising installing a back box in a wall such that said back box is flush with an exterior side of said wall. Subsequently, the method couples an adapter plate assembly to said back box on said exterior side of said wall, thereby forming a substantially weather proof seal between a back side of said adapter plate assembly and said exterior side of said wall, wherein said adapter plate assembly comprises a plate, wherein said plate comprises at least one mounting member for receiving a notification appliance and at least one mounting member for receiving said back box, a first gasket coupled to a front side of said plate and a second gasket coupled to a back side of said plate. The method concludes by coupling a notification appliance to said adapter plate assembly, thereby forming a substantially weather proof seal between said front side of said plate and said notification appliance. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       So that the manner in which the above recited features of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments. 
         FIG. 1  is a front, back and side view of an exemplary adapter plate assembly of the present invention; 
         FIG. 2  is a front, back and side view of an alternate exemplary adapter plate assembly of the present invention; 
         FIG. 3  is a front, back and side view of an exemplary plate of an exemplary adapter plate assembly of the present invention; 
         FIG. 4  is a front, back and side view of an alternate exemplary plate of an alternate exemplary adapter plate assembly of the present invention; 
         FIG. 5  is an engineering drawing of an exemplary front gasket of the present invention; 
         FIG. 6  is an engineering drawing of an exemplary rear gasket of the present invention; and 
         FIG. 7  is an exploded isometric view of an exemplary installation of an exemplary adapter plate assembly of the present invention. 
     
    
    
     To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures. 
     DETAILED DESCRIPTION 
     The present invention generally discloses an adapter plate assembly for outdoor notification appliances that can eliminate the need to mount unsightly back boxes and run unsightly conduits on the exterior walls of buildings. As discussed above, to maintain the aesthetic appeal of buildings, it is desirable to have a minimum number of parts protruding from or visible on exterior walls of buildings. However, by code, some buildings may be required to install notification appliances to the exterior walls of buildings. Notification appliances may be for example, audio alarms e.g., speakers, visual alarms e.g., strobe lights, or any combination thereof. The buildings may be commercial buildings that have outdoor patronage such as for example, outdoor eateries, outdoor shopping malls and the like. Therefore, maintaining the aesthetic appeal of the exterior of buildings may be important to attract a higher number of patrons or simply to promote the personal enjoyment of the building. 
     In one embodiment,  FIG. 1  illustrates an adapter plate assembly  100  of the present invention. The adapter plate assembly  100  comprises a plate  102 , a first gasket  104  coupled to a front side of the plate  102  and a second gasket  106  coupled to a back side of the plate  102 . The plate  102  may be fabricated from steel, for example cold rolled steel (CRS). In an exemplary embodiment, 16 gauge CRS is used for fabricating plate  102  to a thickness of approximately 0.040 inches (in.) to 0.060 in. 
     The first gasket  104  and second gasket  106  are fabricated from any material suitable for use in outdoor applications that may withstand outdoor weather conditions, such as moisture, rain, wind and the like. For example, a suitable material may be monomers. In an exemplary embodiment of the present invention, the first gasket  104  and second gasket  106  may be fabricated from ethylene propylene diene monomer (EPDM) having a density of approximately 4 to 7 pounds per cubic foot (lbs/ft 3 ). 
     In an exemplary embodiment, the second gasket  106  is thicker than the first gasket  104 . The second gasket  106  is thicker to allow the second gasket  106  to extend beyond a lip  130  of plate  102 . Consequently, when the back side of plate  102  is coupled to a back box, the second gasket  106  may be compressed to form a weather proof seal. Exemplary dimensions of the first gasket  104  and the second gasket  106  are discussed below with reference to  FIGS. 5 and 6 . 
     The first gasket  104  and the second gasket  106  are coupled to the front side and back side, respectively, of plate  102  using an adhesive. In an exemplary embodiment, the adhesive may be any acrylic adhesive. Furthermore, the adhesive may be placed on the first gasket  104  and second gasket  106  with a “strip-off” adhesive. “Strip-off” adhesives may be any adhesive with a non-adhesive backing that may be removed to expose the adhesive on the gaskets. Consequently, during fabrication, the first gasket  104  and second gasket  106  may be directly applied to the plate  102  with the “strip-off” adhesive. 
     The plate  102  also includes guide members  108 . The guide members  108  may be designed into the metal stamping of plate  102  and bent or formed to a 90 degree angle relative to the front side of plate  102 . The guide members  108  help during metal stamping of plate  102  to provide the flattest surface possible. Alternatively, guide members  108  may be constructed onto plate  102  separately. The guide members  108  may be strategically placed along an inner edge  126  of plate  102 . The guide members  108  help to ensure proper positioning of the first gasket  104  between the inner edge  126  and an outer edge  124  of plate  102 . 
     The plate  102  also includes at least one mounting member  120  for receiving or mounting a notification appliance and at least one mounting member  122  for receiving a back box. In an exemplary embodiment, the plate  102  has two mounting members  120  for receiving a notification appliance and two mounting members  122  for receiving a back box, as illustrated in  FIG. 1 . Mounting members  120  may include tapped holes  110  and  112  for receiving a screw to couple plate  102  to a notification appliance. Mounting members  122  may include mounting holes  114  and  116  to couple plate  102  to a back box. Mounting holes  114  and  116  may be punched through in an oval or wider geometry than tapped holes  110  and  112  to provide a proper tolerance. One skilled in the art will recognize that the present invention is not limited to any specific number of mounting members  120  for receiving a notification appliance or mounting members  122  for receiving a back box. Any number of mounting members  120  and  122  sufficient to couple the plate  102  to a notification appliance or back box, respectively, are within the scope of the present invention. Furthermore, one skilled in the art will recognize that the positioning of mounting members  120  and  122  to receive a notification appliance or a back box, respectively, may be deployed in any position such as for example, a single gang, double gang or 4 inch position. 
     The plate  102  also comprises at least one opening  118 . The opening  118  provides a passage for wiring from a conduit to be connected to a notification appliance coupled to the front side of plate  102 . The opening  118  is formed by inner edges  126  of plate  102 . Moreover, in an exemplary embodiment, opening  118  is deployed in a center of plate  102 . One skilled in the art will recognize that plate  102  may have more than one opening  118  and the present invention is not limited to a single opening  118 . For example, plate  102  may have multiple openings  118  to organize or separate specific wiring from the conduit. Moreover, one skilled in the art will recognize that opening  118  may be in any position relative to plate  102  to allow wiring to pass through the plate  102  from a conduit to a notification appliance coupled to the front side of plate  102 . 
     An alternative adapter plate assembly  200  is illustrated in  FIG. 2 . The adapter plate assembly  200 , similar to adapter plate assembly  100 , comprises a plate  202 , a first gasket  204  coupled to a front side of the plate  202  and a second gasket  206  coupled to a back side of the plate  202 . The plate  202  may be fabricated from steel, for example cold rolled steel (CRS). In an exemplary embodiment, 16 gauge CRS is used for fabricating plate  202  to a thickness of approximately 0.040 in. to 0.060 in. 
     The first gasket  204  and second gasket  206  are fabricated from any material suitable for use in outdoor applications and that may withstand outdoor weather conditions, such as moisture, rain, wind and the like. For example, a suitable material may be monomers. In an exemplary embodiment of the present invention, the first gasket  204  and second gasket  206  may be fabricated from ethylene propylene diene monomer (EPDM) having a density of approximately 4 to 7 lbs/ft 3 . 
     In an exemplary embodiment, the second gasket  206  is thicker than the first gasket  204 . The second gasket  206  is thicker to allow the second gasket  206  to extend beyond a lip  230  of plate  202 . Consequently, when the back side of plate  202  is coupled to a back box, the second gasket  206  may be compressed to form a weather proof seal. Exemplary dimensions of the first gasket  204  and the second gasket  206  are discussed below with reference to  FIGS. 5 and 6 . 
     The first gasket  204  and the second gasket  206  are coupled to the front side and back side, respectively, of plate  202  using an adhesive. In an exemplary embodiment, the adhesive may be any acrylic adhesive. Furthermore, the adhesive may be placed on the first gasket  204  and second gasket  206  with a “strip-off” adhesive. “Strip-off” adhesives may be any adhesive with a non-adhesive backing that may be removed to expose the adhesive on the gaskets. Consequently, during fabrication the first gasket  204  and second gasket  206  may be directly applied to the plate  202  with the “strip-off” adhesive. 
     The plate  202  also includes guide members  208 . The guide members  208  may be designed into the metal stamping of plate  202  and bent or formed to a 90 degree angle relative to the front side of plate  202 . The guide members  208  help during metal stamping of plate  202  to provide the flattest surface possible. Alternatively, guide members  208  may be constructed onto plate  202  separately. The guide members  208  may be strategically placed along an inner edge  214  of plate  202 . The guide members  208  help to ensure proper positioning of the first gasket  204  between the inner edge  214  and an outer edge  212  of plate  202 . 
     The plate  202  also includes at least one mounting member  210  for receiving or mounting a notification appliance and a back box. In an exemplary embodiment, the plate  202  has two mounting members  210  for receiving a notification appliance and a back box, as illustrated in  FIG. 2 . Mounting members  210  include at least one tapped hole  226  for receiving a screw to couple plate  202  to a notification appliance. In an exemplary embodiment, mounting members  210  include a single tapped hole  226  for receiving a notification appliance. Mounting members  210  also include at least one mounting hole  222  and at least one mounting hole  224  to couple plate  202  to a back box. In an exemplary embodiment, mounting members  210  may include multiple mounting holes  222  and multiple mounting holes  224  for receiving a back box. Multiple mounting holes  222  may be positioned such that plate  202  may be coupled to a back box in a single gang, double gang or 4 inch position. Mounting holes  224  may be punched through in an oval or wider geometry than mounting holes  222  to provide a proper tolerance. One skilled in the art will recognize that the present invention is not limited to any specific number of mounting members  210  for receiving a notification appliance and a back box. Any number of mounting members  210  sufficient to couple the plate  202  to a notification appliance or back box is within the scope of the present invention. Furthermore, one skilled in the art will recognize that the positioning of mounting members  210  to receive a notification appliance or a back box, respectively, may be in any position such as for example, a single gang, double gang or 4 inch position. 
     The plate  202  also comprises at least one opening  218 . The opening  218  provides a passage for wiring from a conduit to be connected to a notification appliance coupled to the front side of plate  202 . The opening  218  is formed by inner edges  214  of plate  202 . Moreover, in an exemplary embodiment, opening  218  is in a center of plate  202 . One skilled in the art will recognize that plate  202  may have more than one opening  218  and the present invention is not limited to a single opening  218 . For example, plate  202  may have multiple openings  218  to organize or to separate specific wiring from the conduit. Moreover, one skilled in the art will recognize that opening  218  may be in any position relative to plate  202  to allow wiring to pass through the plate  202  from a conduit to a notification appliance coupled to the front side of plate  202 . 
       FIGS. 3 and 4  illustrate exemplary dimensions of plates  102  and  202 , respectively. Plates  102  and  202  may comprise a square geometry each side measuring approximately 5 in. to 6 in. in length. One skilled in the art will recognize that plates  102  and  202  may be in any geometry or have any perimeter dimensions. However, to achieve the goal of maintaining aesthetic appeal on the exterior of a building, plates  102  and  202  should be fabricated to match the perimeter dimensions of a mounting base of a notification appliance in an exemplary embodiment. 
     In addition, plates  102  and  202  should be relatively flat. In an exemplary embodiment of the present invention, plates  102  and  202  have a flatness within approximately 0.015 to 0.025 inches Total Indicator Reading (TIR). The remaining dimensions of plates  102  and  202  are illustrated in  FIGS. 3 and 4 , respectively. The dimensions are provided only as examples and are not limiting in any way. 
     An exemplary embodiment of the first gasket  104  and  204  is illustrated in  FIG. 5 . The gasket illustrated in  FIG. 5  will be generally referred to as first gasket  104 , but is not intended to be limited to only first gasket  104 . As noted above, the following discussion may equally apply to first gasket  204  of adapter plate assembly  200 . 
     The first gasket  104  is generally shaped to match the geometry of plates  102 ,  202 . In an exemplary embodiment, the first gasket  104  has a square geometry with each side being approximately 5 in. to 6 in. in length. The first gasket  104  may also have a center opening to correspond to the size and position of openings  118 ,  218  of plates  102 ,  202 , respectively. The first gasket  104  is applied to the front side of plates  102 ,  202 . 
     Furthermore, the first gasket  104  should have a thickness that is sufficient to create a weather proof seal between the plates  102 ,  202  and a notification appliance coupled to the front side of plates  102 ,  202 . A weather proof seal is defined herein as preventing any weather element from entering the inside of the notification appliance or back box. Weather elements may be, for example, moisture, rain, snow, hail, excessive sun-light, wind and the like. The thickness of the first gasket  104  required to create a weather proof seal will be correlated to the properties of the material chosen to fabricate the first gasket  104 . In an exemplary embodiment, the thickness is approximately 0.075 in. to 0.175 inches for a first gasket  104  fabricated from EPDM having a density of approximately 4 to 7 lbs/ft 3 . When a notification appliance is coupled to the front side of plate  102 ,  202 , the first gasket  104  may compressed to approximately half of the original thickness. 
     High ultra-violet (UV) resistance and low flammability may be optional features of the first gasket  104 . For example, to prevent the inside of the notification appliance and back box from being exposed to excess sun-light, the material of the first gasket  104  should be rated for a high resistance to ultra-violet light. In addition, the material may have flammability standards that meet Underwriters Laboratories (UL) standards for certain applications, for example, UL code JMST2. 
     An exemplary second gasket  106  and  206  is illustrated in  FIG. 6 . The gasket illustrated in  FIG. 6  will be generally referred to as second gasket  106 , but is not intended to be limited to only second gasket  106 . As noted above, the following discussion may equally apply to second gasket  206  of adapter plate assembly  200 . 
     The second gasket  106  is generally shaped to match the geometry of plates  102 ,  202 . In an exemplary embodiment, the second gasket  106  has a square geometry with each side being approximately 5 in. to 6 in. in length. The second gasket  106  may also have a center opening to correspond to the size and position of openings  118 ,  218  of plates  102 ,  202 , respectively. The second gasket  106  is applied to the front side of plates  102 ,  202 . 
     Furthermore, the second gasket  106  should have a thickness that is sufficient to create a weather proof seal between the plates  102 ,  202  and a back box coupled to the back side of plates  102 ,  202 . Also as noted above, the thickness of the second gasket  106  will be dependent on the dimensions of lip  130 ,  230  of plates  102 ,  202 . The thickness of the second gasket  106  required to create a weather proof seal will be further correlated to the properties of the material chosen to fabricate the second gasket  106 . In an exemplary embodiment, the thickness is approximately 0.400 in. to 0.600 in. for a second gasket  106  fabricated from EPDM having a density of approximately 4 to 7 lbs/ft 3 . When the back side of plate  102 ,  202  is coupled to a back box and an exterior side of a wall, the second gasket  106  may be compressed to approximately half of the original thickness. 
     High ultra-violet (UV) resistance and low flammability may also be optional features of the second gasket  106 . For example, to, prevent the inside of the notification appliance and back box from being exposed to excess sun-light, the material of the second gasket  106  should be rated for a high resistance to ultra-violet light. In addition, the material may have flammability standards that meet Underwriters Laboratories (UL) standards for certain applications, for example, UL code JMST2. 
     An exemplary installation of the adapter plate assembly  100  of the present invention is illustrated in  FIG. 7 . One skilled in the art will recognize that adapter plate assembly  200  may be installed in a similar fashion. A back box  704  is installed into a wall  714 . The wall  714  may be any exterior wall of any commercial or residential building or structure. Notably, the back box  704  is flush with an exterior side of wall  714 . A conduit (not shown) is run on an interior side of wall  714  into back box  704 . Consequently, the conduit and back box  704  cannot be seen from the exterior of the wall  714 . 
     Subsequently, the back side of the plate  102  may be coupled to the back box  704  and a notification appliance  702  may be coupled to the front side of the plate  102  via screws  706 ,  708 ,  710  and  712 . The back side of plate  102  lies flat against wall  714 . The second gasket  106  forms a weather proof seal between the back side of plate  102  and the exterior side of wall  714  and the back box  704 . The first gasket  104  forms a weather proof seal between the front side of plate  102  and the notification appliance  702 . 
     An optional step may include caulking the edges of the back side of the plate  102  and the exterior side of wall  714 . Caulking may further ensure that the seal between the back side of plate  102  and the exterior side of wall  714  is weather proof. 
     It should be noted that the present disclosure provides various numerical values that are only exemplary. Those skilled in the art will realize that other values may be applicable and thus, these exemplary values should not be viewed as a limitation of the present invention. 
     While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.