Patent Abstract:
A self-trimming in-wall receptacle and method therefor, comprising a receptacle having a storage area, a trim and a coupling mechanism that allows a person to insert the receptacle into an opening in a wall. The receptacle is self-trimming and easy to couple to a wall, eliminating the need for complicated installation. The self-trimming in-wall receptacle can substantially flush-mount wall-mounted electrical objects such as smoke detectors, air conditioning control units, alarm keypads, doorbell chime boxes and the like, as well as store other objects.

Full Description:
RELATED APPLICATION  
       [0001]     This application is a continuation in part of copending U.S. patent application Ser. No. 10/843,768, filed on May 12, 2004. 
     
    
     FIELD OF THE INVENTION  
       [0002]     This invention relates generally to in-wall receptacles and methods therefor and, more specifically, to a self-trimming in-wall receptacle that may be flush-mounted in an opening in drywall.  
       BACKGROUND OF THE INVENTION  
       [0003]     Virtually all residential and commercial construction includes smoke detectors and air conditioning control units. These devices are almost always mounted externally on an interior wall, protruding several inches from the surface of the wall. In addition, residential construction typically includes doorbell chime boxes, which also protrude from the wall. External, wall-mounted devices are not only unaesthetic, they can cause injury to a passerby. They are also against the trend of modern construction, which is toward smooth interior wall surfaces with as few protrusions as possible.  
         [0004]     It is commonplace to flush-mount electrical outlets inside both commercial and residential buildings. Typically, the outlet is coupled to a stud, and it is exposed through an opening in the drywall. A plate is then secured over the electrical box to hide its contents; i.e., these receptacles are not flush-mounted with trim. Light switches are similarly mounted.  
         [0005]     A need exists for a self-trimming in-wall receptacle having a storage area and being capable of being inserted into an opening in a wall and coupled to the wall, while at the same time the receptacle has a trim that is dimensioned to cover the edge of the opening.  
         [0006]     The present invention satisfies these needs and provides other, related advantages.  
       SUMMARY OF THE INVENTION  
       [0007]     An object of the present invention is to provide a device capable of substantially flush-mounting wall-mounted objects that are usually externally mounted in a self-trimming receptacle.  
         [0008]     A further object of the present invention is to provide a device capable of storing objects in an interior space behind a wall.  
         [0009]     It is a further object of the present invention to provide a method for installing a self-trimming in-wall receptacle.  
       BRIEF DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0010]     In accordance with one embodiment of the present invention, a self-trimming in-wall receptacle is disclosed, comprising, in combination: a receptacle having an open end and a closed end and defining a storage area therebetween; a trim coupled to and extending from an outer edge of the open end of the receptacle; and at least one coupling mechanism coupled to the receptacle and dimensioned to couple the receptacle to a wall so that an inner surface of the trim is proximate an outer surface of the wall, an inner surface of the coupling mechanism is proximate an inner surface of the wall, and the closed end of the receptacle is housed inside an interior space behind the wall, wherein the trim, the receptacle, and the coupling mechanism form a one-piece assembly.  
         [0011]     In accordance with another embodiment of the present invention, a method for installing a self-trimming in-wall receptacle is disclosed, comprising, in combination, the steps of: providing a receptacle having an open end and a closed end and defining a storage area therebetween; wherein the receptacle further comprises a trim coupled to and extending from an outer edge of the open end of the receptacle and at least one coupling mechanism coupled to the receptacle and dimensioned to couple the receptacle to a wall; wherein the trim and the receptacle and the at least one coupling mechanism form a one-piece assembly; cutting an aperture in a wall, wherein the aperture has an internal periphery greater than an outer periphery of the closed end of the receptacle and smaller than the outer periphery of the trim; positioning the receptacle within the aperture in an orientation that is slightly counterclockwise so that the receptacle is substantially non-parallel to a ground below the receptacle and the wall; and turning the receptacle to a position that is substantially parallel to the ground below, so that an inner surface of the at least one coupling mechanism is proximate an inner surface of the wall, an inner surface of the trim is proximate an outer surface of the wall, and the closed end of the receptacle is housed inside an interior space behind the wall, thereby coupling the receptacle to the wall.  
         [0012]     The foregoing and other objects, features, and advantages of the invention will be apparent from the following, more particular description of the preferred embodiments of the invention, as illustrated in the accompanying drawings.  
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0013]      FIG. 1  is a front, perspective view of one embodiment of the self-trimming in-wall receptacle of the present invention.  
         [0014]      FIG. 2  is a back, perspective view of the self-trimming in-wall receptacle of  FIG. 1 .  
         [0015]      FIG. 3  is a side view of the self-trimming in-wall receptacle of  FIG. 1 , showing the receptacle coupled to a wall (shown in phantom) with the closed end of the receptacle being housed inside an interior space behind a wall.  
         [0016]      FIG. 4  is a back view of a section of drywall, showing a pattern for an aperture cut out of the drywall, consistent with an embodiment of the present invention.  
         [0017]      FIG. 5  is a back view of the self-trimming in-wall receptacle of  FIG. 1 , showing the receptacle being inserted into an aperture cut out of the drywall.  
         [0018]      FIG. 6  is a back view of the self-trimming in-wall receptacle of  FIG. 1 , showing the receptacle coupled to drywall with the closed end of the receptacle being housed inside an interior space behind the drywall.  
         [0019]      FIG. 7  is a back, perspective view of the self-trimming in-wall receptacle of  FIG. 1 , showing the receptacle being inserted into an aperture cut out of drywall.  
         [0020]      FIG. 8  is a back, perspective view of the self-trimming in-wall receptacle of  FIG. 1 , showing the receptacle coupled to drywall with the closed end of the receptacle being housed inside an interior space behind the drywall.  
         [0021]      FIG. 9  is a front, perspective view of another embodiment of the self-trimming in-wall receptacle of the present invention, showing an air conditioning control unit disposed in the storage area.  
         [0022]      FIG. 10  is a back, perspective view of the self-trimming in-wall receptacle of  FIG. 9 .  
         [0023]      FIG. 11  is a back view of the self-trimming in-wall receptacle of  FIG. 9 , showing the receptacle being inserted into an aperture cut out of drywall.  
         [0024]      FIG. 12  is a back view of the self-trimming in-wall receptacle of  FIG. 9 , showing the receptacle coupled to drywall with the closed end of the receptacle being housed inside an interior space behind the drywall.  
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0025]     Referring to  FIGS. 1-3  and  5 - 8 , reference number  10  refers generally to one embodiment of the self-trimming in-wall receptacle of the present invention. The self-trimming in-wall receptacle  10  comprises a receptacle  12  having an open end  14  (shown in  FIG. 1 ) enclosed by a transparent covering  24  (shown in  FIG. 1 ) and a closed end  16  (shown in  FIGS. 2 and 5 - 7 ) and defining a storage area  18  (shown in  FIG. 1 ) therebetween. The self-trimming in-wall receptacle  10  further comprises a trim  20  coupled to and extending from an outer edge of the open end  14  of the receptacle  12 . The receptacle  12  and the trim  20  form a one-piece assembly and may be injection molded. Preferably, the receptacle  12  and the trim  20  are composed of high-impact injection molded thermal plastic, although substantial benefit could be derived from other injection molded materials, such as polyvinyl chloride and the like.  
         [0026]     The self-trimming in-wall receptacle  10  further comprises at least one coupling mechanism, to permit attachment of the receptacle  10  to drywall without the need to secure the receptacle  12  to a stud. Preferably, there is friction to substantially retain the orientation of the receptacle  10  on the drywall. In one embodiment (shown in  FIGS. 2, 3 , and  5 - 8 ), the coupling mechanism comprises four tabs  22 . As shown in  FIGS. 2-3 , the tabs  22  may be disposed along the sides of the receptacle  12 , and spaced rearward of the interior surface  40  of the trim  20  by approximately the thickness of a wall  30 . In one embodiment, the tabs  22  are part of an overall one-piece assembly including the receptacle  12  and the trim  20 . While in this embodiment four tabs  22  are used, more or less tabs  22  may be used, as desired.  
         [0027]     It should be noted that one tab  22  may be sufficient to securely couple the receptacle  12  to the wall  30 . Preferably, the tabs  22  are positioned in such a way that one tab  22  protrudes from each of the four sides of the receptacle  12 . However, it would be possible to place the tabs  22  in a different arrangement, so long as the tabs  22  accomplish the same function of coupling the receptacle  12  to the wall  30 .  
         [0028]     Referring now to  FIGS. 9-12 , reference number  100  refers generally to another embodiment of the self-trimming in-wall receptacle of the present invention. The self-trimming in-wall receptacle  100  is substantially the same as the self-trimming in-wall receptacle  10 , except that in the self-trimming in-wall receptacle  100 , a frame  22   a  is used instead of the tabs  22  to secure the self-trimming in-wall receptacle  100  to the wall  30  (shown in  FIGS. 11 and 12 ). For this reason, the same reference numbers used in describing the features of the self-trimming in-wall receptacle  10  will be used when describing the identical features of the self-trimming in-wall receptacle  100 .  
         [0029]     In this embodiment (shown in  FIGS. 9-12 ), the coupling mechanism comprises a frame  22   a . Preferably, the frame  22   a  is disposed along the sides of the receptacle  12 , and spaced rearward of the interior surface  40  (shown in  FIGS. 10-12 ) of the trim  20  (shown in  FIGS. 9 and 10 ) by approximately the thickness of the wall  30 . The frame  22   a  may consist of a separate piece that is coupled to the receptacle  12  in some manner, or the frame  22   a  may be part of an overall one-piece assembly of the self-trimming in-wall receptacle  100 . Preferably, the frame  22   a  is substantially rectangular shaped. Further, preferably, the frame  22   a  is positioned in such a manner that is slightly diagonal to a floor below when the self-trimming in-wall receptacle  100  is secured in position on the wall  30 .  
         [0030]     The tabs  22  of the self-trimming in-wall receptacle  10  and the frame  22   a  of the self-trimming in-wall receptacle  100  are dimensioned to couple the receptacle  12  to a wall  30  (shown in FIGS.  3 ,  5 - 8 , and  11 - 12 ), so that an inner surface  40  (shown in  FIGS. 2, 7 ,  8 , and  10 - 12 ) of the trim  20  is proximate an outer surface  32  (shown in  FIG. 3 ) of the wall  30  and an inner surface  23  of the tabs  22  (shown in  FIG. 3 ) or an inner surface  23   a  of the frame  22   a  (shown in  FIG. 9 ) is proximate an inner surface  33  (shown in  FIG. 3 ) of the wall  30 . When the receptacle  12  is coupled to the wall  30 , the closed end  16  of the receptacle  12  is housed inside an interior space  34  (shown in  FIGS. 5-8 ,  11 , and  12 ) behind the wall  30 .  
         [0031]     In one embodiment of the self-trimming in-wall receptacle  10  and another embodiment of the self-trimming in-wall receptacle  100  of the present invention, a covering  24  (shown in  FIGS. 1 and 9 ) is coupled to the receptacle  12  proximate the open end  14 . The covering  24  is dimensioned to cover the open end  14  of the receptacle  12 . It should be clearly understood that the covering  24  may be hingedly coupled to the receptacle  12 , or coupled in some other way (such as slidably or removably), so long as the covering  24  is capable of covering the open end  14  of the receptacle  12 . In one embodiment of the self-trimming in-wall receptacle  10  (shown in  FIG. 1 ) and another embodiment of the self-trimming in-wall receptacle  100  (shown in  FIG. 9 ), the covering  24  is dimensioned to be substantially flush with the open end  14  of the receptacle  12 . The covering  24  may define slits (not shown) or other apertures, in order to vent the storage area  18  of the receptacle  12 . End portions of the covering  24  may define slits or a front surface of the covering  24  may define slits. Slits in end portions of the covering  24  may be more beneficial for venting heat, whereas slits in the front surface of the covering  24  may provide for better passage of sound waves for devices such as a doorbell chime sound generating device (not shown). In addition, it should be clearly understood that the covering  24  may be comprised of opaque plastic, translucent plastic, cloth, metal, glass, or any other kind of material so long as that material is capable of covering the open end  14  of the receptacle  12 . While in the preferred embodiments the self-trimming in-wall receptacle  10  and self-trimming in-wall receptacle  100  comprise a covering  24 , it should be clearly understood that substantial benefit could be derived from an alternative configuration of the self-trimming in-wall receptacle  10  or self-trimming in-wall receptacle  100  in which there is no covering  24 .  
         [0032]     Referring now to  FIGS. 1 and 9 , in one embodiment of the self-trimming in-wall receptacle  10  and another embodiment of the self-trimming in-wall receptacle  100  of the present invention, the covering  24  comprises at least one locking device  28  dimensioned to lock the covering  24  in a closed position over the open end  14  of the receptacle  12 . The at least one locking device  28  is preferably coupled to the covering  24 , although it should be clearly understood that substantial benefit could be derived from an alternative embodiment of the present invention in which the at least one locking device  28  is coupled to the receptacle  12  or the trim  20 , so long as the at least one locking device  28  is capable of locking the covering  24  in a closed position with the covering  24  covering the open end  14  of the receptacle  12 . It may be desired for the at least one locking device  28  to comprise a locking tab (not shown) dimensioned to be inserted into at least one slot (not shown) defined by the receptacle  12  or the covering  24 .  
         [0033]     In preferred embodiments, the self-trimming in-wall receptacle  10  and self-trimming in-wall receptacle  100  further comprise a key (not shown) dimensioned to be inserted into the at least one locking device  28  and turned to initiate locking of the covering  24 . It may be desired for locking of the covering  24  to be accomplished by insertion of the locking tab into the at least one slot. In addition, the key may be used to open the covering  24  by removing the locking tab from the at least one slot. While in preferred embodiments the self-trimming in-wall receptacle  10  and self-trimming in-wall receptacle  100  comprise a covering  24  having a locking device  28 , it should be clearly understood that substantial benefit could be derived from an alternative embodiment of the present invention in which there is a different type of locking mechanism or in which there is no locking device  28 .  
         [0034]     In one embodiment of the self-trimming in-wall receptacle  10  of the present invention, shown in  FIG. 7 , the closed end  16  of the receptacle  12  defines at least one aperture  38  dimensioned to permit electrical wiring (not shown) to pass therethrough.  
         [0035]     In additional embodiments of the self-trimming in-wall receptacle  10  and self-trimming in-wall receptacle  100  of the present invention, shown in  FIGS. 2, 5 ,  6 , and  10 - 12 , the closed end  16  of the receptacle  12  defines a plurality of perforations  39  dimensioned to allow a person (not shown) to remove at least a portion of the closed end  16  of the receptacle  12  to permit electrical wiring to pass therethrough. In this way, a person may “punch-out” sections of the closed end  16  of the receptacle  12  in order to create apertures  38  or other spaces defined by the closed end  16  to allow for electrical wiring to pass therethrough.  
         [0036]     While in the various embodiments of the self-trimming in-wall receptacle  10  and the self-trimming in-wall receptacle  100  the coupling mechanisms shown in the figures are described as a plurality of tabs  22  or a frame  22   a , it should be clearly understood that substantial benefit could be derived from further securing the receptacle  12  to a wall  30  with an additional type of coupling mechanism. For example, it is within the spirit and scope of the invention that an outer surface of the closed end  16  of the receptacle  12  could be coupled with a coupling mechanism  22  directly to an interior surface of an opposite wall  30  on the other side of the interior space  34 .  
         [0037]     As described above, there are various ways to further couple the self-trimming in-wall receptacle  10  and self-trimming in-wall receptacle  100  to a wall  30 . It may be desired to further secure the self-trimming in-wall receptacle  10  or self-trimming in-wall receptacle  100  in place by inserting screws (not shown) or the like through the trim  20  and into the wall  30 . It may also be desired to further secure the self-trimming in-wall receptacle  10  or self-trimming in-wall receptacle  100  in place through the use of an adhesive, such as glue, an adhesive strip, or some other type of adhesive contacting interior surface  40 .  
         [0038]     In another embodiment (not shown) of the self-trimming in-wall receptacle  10  and self-trimming in-wall receptacle  100  of the present invention, the receptacle  12  has a width approximately equal to the distance between two wall studs. In this embodiment, the coupling mechanism  22  may further comprise at least one screw inserted through a side of the receptacle  12  and into a wall stud so as to couple the receptacle  12  to the wall  30 . In typical 2×4 or 2×6 construction, a wall stud is placed approximately every 24 inches. With each stud approximately 0.75 inches wide, this leaves approximately 22.5 inches for the width of the receptacle  12  in order to be able to couple the receptacle  12  directly to wall studs on either side.  
         [0039]     The storage area  18  of the self-trimming in-wall receptacle  10  and self-trimming in-wall receptacle  100  can house an air conditioning control unit  19  (shown in  FIGS. 1 and 9 ), a doorbell chime sound generating device (not shown), alarm keypads (not shown), rifles (not shown), electronic timers (not shown), switches (not shown), valves (not shown), personal items, such as jewelry (not shown) or other items of value, or other desired objects. It may be desired to include within the storage area  18  or proximate thereto a light source, by which the storage area may be illuminated.  
         [0040]     In the preferred embodiment of the present invention, shown in  FIGS. 1-12 , the distance between the closed end  16  and the open end  14  of the receptacle  12  is approximately 4 inches for 2×4 construction and approximately 6 inches for 2×6 construction, although it should be clearly understood that substantial benefit could be derived from an alternative configuration of the present invention in which the depth of the receptacle  12  is 8 inches, 12 inches, or more, if a void behind the wall  30  is sufficiently deep. The width of the receptacle  12  is preferably between approximately 4 inches and approximately 22.5 inches. Preferably, the trim  20  extends approximately 0.5 inches to approximately 1.5 inches from the outer edge of the open end  14  of the receptacle  12 . The height of the receptacle  12  is limited only by the distance between the floor and the ceiling, making it possible, therefore, to provide a long, substantially rectangular receptacle  12  capable of storing relatively long objects, such as rifles.  
         [0041]     While in the preferred embodiment of the present invention the depth of the receptacle  12  is between approximately 4 inches and 6 inches, the width of the receptacle  12  is between approximately 4 inches and 22.5 inches, and the length of the trim is between approximately 0.5 inches and approximately 1.5 inches, it should be clearly understood that substantial benefit could be derived from an alternative configuration of the self-trimming in-wall receptacle  10  or self-trimming in-wall receptacle  100  in which different sizes are used, even those that deviate, even substantially, from the preferred measurements, in either direction.  
       Statement of Operation  
       [0042]     Referring to  FIGS. 4 and 7 , in order to make use of the self-trimming in-wall receptacle  10 , one must first cut an aperture  36  into the wall  30 . The aperture  36  must have an internal periphery greater than the outer periphery of the closed end  16  of the receptacle  12 . At the same time, the aperture  36  must have an internal periphery smaller than the outer periphery of the trim  20 . Preferably, the wall  30  is drywall, and the implement used to create the aperture  36  is a handsaw  37  (shown in  FIG. 4 ), knife (not shown) or other sharp implement. However, it should be clearly understood that substantial benefit could be derived from installing the self-trimming in-wall receptacle  10  into a wall made of another type of material, such as wood, foam, metal, plastic, etc., using either the same cutting implements mentioned above or alternative cutting mechanisms. Preferably, the wall is an interior wall of a structure. However, it should be understood that substantial benefit could be derived from installing the self-trimming in-wall receptacle  10  in an outer wall of a structure.  
         [0043]     Referring now to  FIGS. 3, 5 ,  6 ,  11 , and  12 , after the aperture  36  has been cut out of the wall  30 , the closed end  16  of the receptacle  12  is inserted into the wall  30  through the aperture  36  so that the closed end  16  of the receptacle  12  is housed inside an interior space  34  behind the wall  30 . At the same time, an inner surface of the trim  20  rests proximate an outer surface  32  of the wall  30  (as shown in  FIG. 3 ) and an inner surface  23  of the tabs  22  (shown in  FIG. 3 ) or an inner surface  23   a  of the frame  22   a  (shown in  FIG. 9 ) rests proximate an inner surface  33  (shown in  FIG. 3 ) of the wall  30 . The receptacle  12  is coupled securely to the wall  30  through the use of either the tabs  22  or frame  22   a . In the preferred embodiments, the self-trimming in-wall receptacle  10  or self-trimming in-wall receptacle  100  is first tilted slightly counter-clockwise (as shown in  FIGS. 5, 7 , and  11 ) and then placed through the aperture  36  until the trim  20  rests proximate an outer surface  32  of the wall  30  (as shown in  FIGS. 5 and 11 ). The self-trimming in-wall receptacle  10  or self-trimming in-wall receptacle  100  is then tilted back to an upright position, so that the receptacle  12  is substantially parallel to a floor below (as shown in  FIGS. 6, 8 , and  12 ). The tabs  22  or frame  22   a  should be aligned behind the wall  30  in such a way that the self-trimming in-wall receptacle  10  or self-trimming in-wall receptacle  100  is firmly in place.  
         [0044]     As shown by way of example in  FIGS. 4, 7 , and  11 , in one embodiment, part of the lower portion of the aperture  36  is substantially parallel to the ground below the receptacle  12 . In this fashion, when the receptacle  12  is moved to its upright position, a portion of the underside of the receptacle  12  will rest on the portion of the aperture  36  that is parallel to the ground.  
         [0045]     While various methods for coupling the self-trimming in-wall receptacle  10  or self-trimming in-wall receptacle  100  to a wall  30  have been disclosed, it is within the spirit and scope of this invention that alternative coupling methods be used so long as the result is the secure coupling of the receptacle  12  to the wall  30  with the closed end  16  of the receptacle housed in an interior space  34  behind the wall  30  and an interior surface of the trim  20  proximate an outer surface  32  of the wall  30 .  
         [0046]     While the invention has been particularly shown and described with reference to preferred embodiments thereof, it will be understood by those skilled in the art that the foregoing and other changes in form and details may be made therein without departing from the spirit and scope of the invention.

Technology Classification (CPC): 8