Abstract:
A self-trimming in-wall receptacle and method therefor, comprising an injection molded 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.

Description:
FIELD OF THE INVENTION  
       [0001]     This invention relates generally to in-wall receptacles and methods therefor and, more specifically, to a self-trimming in-wall receptacle having a storage area and method therefor.  
       BACKGROUND OF THE INVENTION  
       [0002]     Virtually all residential and commercial construction include 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. The trend of modern construction is towards smooth interior wall surfaces with as few protrusions as possible.  
         [0003]     It is commonplace to flush-mount electrical outlets inside both commercial and residential buildings. Typically, a hole is first cut into the drywall, an electrical box for housing wiring is subsequently inserted into the wall, and a plate is secured over the electrical box to hide its contents. Light switches are similarly mounted.  
         [0004]     For example, U.S. Pat. No. 6,359,219 issued to Reid shows a flush-mount for an electrical circuit box, having multiple apertures and a face plate. The Reid patent is designed to be completely flush-mounted with the wall, using a wall-engaging leg and multiple steps, such as chiseling and using filler material to flush-mount the electrical circuit box. In addition, U.S. Pat. No. 3,334,770 issued to Stanback discloses a cover, door and latch that is attached to an existing electrical control device box. The Stanback device is a cover for an electrical box that otherwise lacks an outward facing trim. The Stanback device requires the additional step of mounting the cover on the electrical box after the electrical box is already mounted in the wall. U.S. Pat. No. 6,444,906 issued to Lewis shows an exterior wall-mounted accessory designed for housing outlets in a vehicle or mobile home. The externally wall-mounted Lewis outlet box comprises a mounting plate and at least one electrical power accessory outlet. In addition, the mounting plate substantially bisects the housing, substantially eliminating any storage area within the housing.  
         [0005]     Thus, a need existed 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 having a trim that is dimensioned to cover the edge of the opening.  
       SUMMARY OF THE INVENTION  
       [0006]     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.  
         [0007]     A further object of the present invention is to provide a device capable of storing objects in an interior space behind a wall.  
         [0008]     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  
       [0009]     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, the receptacle and the trim injection molded to form a one-piece assembly, and a coupling mechanism coupled to the receptacle and dimensioned to couple the receptacle to a wall so that an inner surface of the trim being proximate an outer surface of the wall and the closed end of the receptacle being housed inside an interior space behind the wall.  
         [0010]     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 injection molding a receptacle having an open end and a closed end and defining a storage area therebetween, injection molding a trim coupled to and extending from an outer edge of the open end of the receptacle, the receptacle and the trim forming a one-piece assembly, cutting an aperture in a wall, the aperture having a circumference greater than a circumference of the closed end of the receptacle while at the same time the circumference of the aperture being smaller than a circumference of the trim, inserting the closed end of the receptacle through the aperture, and coupling the receptacle to the wall so that an inner surface of the trim being proximate an outer surface of the wall and the closed end of the receptacle being housed inside an interior space behind the wall.  
         [0011]     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  
       [0012]      FIG. 1  is a perspective view of one embodiment of the self-trimming in-wall receptacle of the present invention, showing an air conditioning control unit disposed in the storage area.  
         [0013]      FIG. 1A  is a perspective view of one embodiment of the self-trimming in-wall receptacle of the present invention, showing a cover dimensioned to cover the open end of the receptacle.  
         [0014]      FIG. 2  is a perspective view of one embodiment of the self-trimming in-wall receptacle of the present invention, showing a plurality of perforated portions of the closed end that allow a person to create apertures by removing the perforated portions.  
         [0015]      FIG. 3  is a perspective view of one embodiment of the self-trimming in-wall receptacle of the present invention, showing an adhesive strip coupled to the rear surface of the trim.  
         [0016]      FIG. 3A  is a perspective view of the self-trimming in-wall receptacle of  FIG. 3 , showing the receptacle being inserted into an aperture cut out of a wall.  
         [0017]      FIG. 3B  is a perspective view of the self-trimming in-wall receptacle of  FIG. 3 , showing the receptacle coupled to a wall with the closed end of the receptacle being housed inside an interior space behind the wall.  
         [0018]      FIG. 4  is a perspective view of one embodiment of the self-trimming in-wall receptacle of the present invention, showing a plurality of gripping arms coupled to the receptacle and dimensioned to secure the receptacle to the wall.  
         [0019]      FIG. 4A  is a perspective view of the self-trimming in-wall receptacle of  FIG. 4 , showing the second end of the gripping arms in contact with an interior surface of the wall, thus securing the receptacle to the wall.  
         [0020]      FIG. 5  is a perspective view of one embodiment of the self-trimming in-wall receptacle of the present invention, showing the receptacle in the shape of a circle and housing a substantially round air conditioning control unit.  
         [0021]      FIG. 5A  is a perspective view of the self-trimming in-wall receptacle of  FIG. 5 , showing a substantially transparent cover covering the open end of the receptacle.  
         [0022]      FIG. 5B  is a perspective view of the self-trimming in-wall receptacle of  FIG. 5 , showing a substantially opaque cover covering the open end of the receptacle.  
         [0023]      FIG. 6  is a perspective view of one embodiment of the self-trimming in-wall receptacle of the present invention, showing a plurality of screws dimensioned to be inserted through a side wall of the receptacle and into wall studs in order to couple the receptacle to the wall.  
         [0024]      FIG. 6A  is a perspective view of the self-trimming in-wall receptacle of  FIG. 6 , showing two rifles stored vertically in the receptacle and a cover covering the open end of the receptacle.  
         [0025]      FIG. 6B  is a perspective view of the self-trimming in-wall receptacle of  FIG. 6 , showing a light source coupled to a top interior surface of the receptacle and dimensioned to illuminate the storage area of the receptacle.  
         [0026]      FIG. 7  is a perspective view of one embodiment of the self-trimming in-wall receptacle of the present invention, showing the receptacle in the shape of a circle and housing a substantially round smoke detector.  
         [0027]      FIG. 7A  is a perspective view of the self-trimming in-wall receptacle of  FIG. 7 , showing a substantially opaque cover covering the smoke detector.  
         [0028]      FIG. 7B  is a perspective view of the self-trimming in-wall receptacle of  FIG. 7 , showing a cover defining a plurality of round slits therein.  
         [0029]      FIG. 8  is a perspective view of one embodiment of the self-trimming in-wall receptacle of the present invention, showing the receptacle in the shape of a rectangle and having a cover defining a plurality of slits. The receptacle is shown housing a substantially rectangular doorbell chime box.  
         [0030]      FIG. 8B  is a perspective view of the self-trimming in-wall receptacle of  FIG. 8 , showing a substantially opaque cover.  
         [0031]      FIG. 9  is a perspective view of one embodiment of the self-trimming in-wall receptacle of the present invention, showing the receptacle in the shape of a rectangle and having jewelry items stored in the storage area.  
         [0032]      FIG. 9A  is a perspective view of the self-trimming in-wall receptacle of  FIG. 9 , showing a substantially opaque cover secured over the open end of the receptacle.  
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0033]     Referring to  FIGS. 1 and 1 A, 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. 1A ) and a closed end  16  (shown in  FIG. 1A ) and defining a storage area  18  (shown in  FIG. 1A ) 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 are injection molded. Preferably, the receptacle  12  and the trim are comprised 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. The self-trimming in-wall receptacle  10  further comprises a coupling mechanism, referred to generically as coupling mechanism  22 . The coupling mechanism  22  is dimensioned to couple the receptacle  12  to a wall  30  (shown in  FIG. 3A ) so that an inner surface  40  (shown in  FIG. 4 ) of the trim  20  is proximate an outer surface  32  (shown in  FIG. 3A ) 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  FIG. 3A ) behind the wall  30 .  
         [0034]     In one embodiment of the self-trimming in-wall receptacle  10  of the present invention, a covering  24  (shown in  FIGS. 1, 1A ,  5 A,  5 B,  6 A,  7 A,  7 B,  8 ,  8 A,  9  and  9 A) 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 ), the covering  24  is dimensioned to be substantially flush with the open end  14  of the receptacle  12 . The covering  24  may define slits  26  (as shown in  FIG. 1A ), or other apertures, in order to vent the storage area  18  of the receptacle  12 . End portions of the covering  24  may define slits  26 , as shown in  FIG. 1A , or a front surface  28  (shown in  FIG. 8 ) may define slits  26 . Slits  26  in end portions of the covering  24  may be more beneficial for venting heat, whereas slits  26  in the front surface  28  of the covering  24  may provide for better passage of sound waves for devices such as a doorbell chime sound generating device  33  (shown in  FIGS. 8 and 8 A). 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 embodiment, the self-trimming in-wall receptacle  10  comprises 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  in which there is no covering  24 .  
         [0035]     Referring now to  FIGS. 1, 1A ,  5 A,  5 B,  6 A,  9  and  9 A, in one embodiment of the self-trimming in-wall receptacle  10  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 . In the preferred embodiment, the at least one locking device  28  comprises a locking tab  29  (shown in  FIGS. 1, 1A ,  5 A,  5 B, and  9 ) dimensioned to be inserted into at least one slot  31  (shown in  FIGS. 1A, 6B , and  9 ) defined preferably by the receptacle  12  (although substantial benefit may be derived from an alternative embodiment of the present invention in which the at least one slot  31  is defined by the covering  24 ).  
         [0036]     In the preferred embodiment, the self-trimming in-wall receptacle  10  further comprises a key  36  (shown in  FIG. 9A ) dimensioned to be inserted into the at least one locking device  28  and turned to initiate locking of the covering  24  by insertion of the locking tab  29  into the slot  31 . In addition, the key  36  may be used to open the covering  24  by removing the locking tab  29  from the slot  31 . While, in the preferred embodiment, the self-trimming in-wall receptacle  10  comprises a covering  24  having a locking mechanism  28  and a locking tab  29  dimensioned to be inserted into a slot  31 , 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 device or in which there is no locking device  28 .  
         [0037]     In one embodiment of the self-trimming in-wall receptacle  10  of the present invention, shown in  FIGS. 1A and 3A , the closed end  16  of the receptacle  12  defines at least one aperture  38  dimensioned to permit electrical wiring (not shown) to pass therethrough.  
         [0038]     In another embodiment of the self-trimming in-wall receptacle  10  of the present invention, shown in  FIGS. 2, 3 ,  4  and  4 A, 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.  
         [0039]     Referring now to  FIGS. 5, 5A ,  5 B,  7 ,  7 A,  7 B, an alternative embodiment of the self-trimming in-wall receptacle  10 , hereinafter  100 , is shown. The self-trimming in-wall receptacle  100  is essentially the same as the self-trimming in-wall receptacle  10 , except that the shape of the self-trimming in-wall receptacle  100  is circular, whereas the shape of the self-trimming in-wall receptacle  10  is rectangular. The self-trimming in-wall receptacle  100  is dimensioned to receive substantially circular objects in the storage area  18 , such as a circular air conditioning control unit  21  (shown in  FIGS. 5 and 5 A), a smoke detector  23  (shown in  FIG. 7 ), or other substantially circular devices. Similarly, a substantially circular covering  24  may be used to cover the open end  14  of the receptacle  12 . The substantially circular covering  24  is similar in all other respects to the standard, rectangular covering  24  described in the other embodiments.  
         [0040]     There are several ways to couple the self-trimming in-wall receptacle  10  to a wall  30 . In one embodiment, shown in  FIGS. 1, 1A ,  5 ,  5 A,  5 B,  8 , and  8 A, the coupling mechanism  22  comprises at least one screw  42  dimensioned to be inserted through the trim  20  of the receptacle  12  and into the wall  30  so as to couple the receptacle  12  to the wall  30 .  
         [0041]     Referring now to  FIG. 3 , an alternative embodiment of the coupling mechanism  22 , hereinafter  22   a , is shown. The coupling mechanism  22   a  performs the same function as the coupling mechanism  22  (i.e. couples the receptacle  12  to the wall  30 ), however the coupling mechanism  22   a  accomplishes this task through the use of an adhesive strip  50 . The adhesive strip  50  is coupled along an interior surface of the trim  20 . Preferably, the adhesive strip  50  comprises a tacky surface  52  for adhering the receptacle  12  to an outer surface  32  of the wall  30  and a removable backing strip  54 , which is coupled to the tacky surface  52  so as to protect the tacky surface  52  prior to use of the adhesive strip  50 .  
         [0042]     Referring now to  FIGS. 4 and 4 A, an alternative embodiment of the coupling mechanism  22 , hereinafter  22   b , is shown. The coupling mechanism  22   b  performs the same function as the coupling mechanism  22  (i.e. couples the receptacle  12  to the wall  30 ), however the coupling mechanism  22   b  accomplishes this task through the use of a plurality of gripping arms  56 . The gripping arms  56  have a first end  58  coupled to the receptacle  12  proximate the closed end  16  and a second end  60  spaced apart from the receptacle  12  and extending to the open end  14  of the receptacle  12  beyond an outer edge of the trim  20 . The gripping arms  56  are dimensioned to permit the closed end  16  of the receptacle  12  to be inserted into a similarly sized aperture  37  (shown in  FIG. 3A ) cut into the wall  30  while at the same time the second end  60  of the plurality of gripping arms  56  are dimensioned to couple the receptacle  12  to an interior surface  35  (shown in  FIG. 4A ) of the wall  30 . Preferably, the gripping arms  56  and the receptacle  12  form a one-piece assembly that is injection molded. Further preferably, the gripping arms  56  are cut-out sections of the receptacle  12 , defining apertures  61  that also serve to ventilate the receptacle  12 . While, in various embodiments of the self-trimming in-wall receptacle  10 , the coupling mechanism  22  comprises alternatively: gripping arms  56 , a tacky surface  52 , and screws  42 , it should be clearly understood that substantial benefit could be derived from an alternative configuration of the self-trimming in-wall receptacle  10  in which some other type of coupling mechanism is used so long as the receptacle is securely coupled to the wall  30 . 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 an adhesive  52 , with a screw  42 , or with some other coupling mechanism  22 ) directly to an interior surface  35  of an opposite wall  30  on the other side of the interior space  34 .  
         [0043]     Referring now to  FIGS. 6, 6A , and  6 B, in a receptacle  12  having a width approximately equal to the distance between two wall studs, the coupling mechanism  22  may comprise at least one screw  42  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.  
         [0044]     The storage area  18  of the self-trimming in-wall receptacle  10  can house an air conditioning control unit  19  (shown in  FIGS. 1 and 3 B), a doorbell chime sound generating device  33  (shown in  FIGS. 8 and 8 A), alarm keypads (not shown), rifles  70  (shown in  FIG. 6A ), electronic timers (not shown), switches (not shown), valves (not shown), personal items, such as jewelry  50  (shown in  FIG. 9 ) or other items of value, or other objects.  
         [0045]     Referring now to  FIG. 6B , a light source  62  is coupled to an interior surface of the receptacle  12  and dimensioned to illuminate the storage area  18 . While, in this embodiment, the self-trimming in-wall receptacle  10  comprises a light source  62 , it should be clearly understood that substantial benefit could be derived from an alternative embodiment of the present invention in which there is no light source  62 .  
         [0046]     In the preferred embodiment of the present invention, shown in  FIGS. 1, 1A ,  2 ,  3 ,  3 A,  3 B,  4 ,  4 A,  8 ,  8 A,  9 , and  9 A 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 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  70  (shown in  FIG. 6A ).  
         [0047]     While, in the preferred embodiment of the present invention, the depth of the receptacle is between approximately 4 inches and 6 inches, the width of the receptacle 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  in which different sizes are used, even those that deviate, even substantially, from the preferred measurements, in either direction.  
       Statement of Operation  
       [0048]     Referring now to  FIG. 3A , in order to make use of the self-trimming in-wall receptacle  10  one must first cut an aperture  37  into the wall  30 . The aperture  37  must have a circumference greater than a circumference of the closed end  16  of the receptacle  12  while at the same time the aperture  37  must have a circumference smaller than a circumference of the trim  20 . Preferably, the wall  30  is drywall, and the implement used to create the aperture  37  is a handsaw (not shown), 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, such as an electric saw, a chainsaw, or other item capable of cutting an aperture  37  out of a wall. 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. After the aperture  37  has been cut out of the wall  30 , the closed end  16  of the injection molded receptacle  12  is inserted into the wall  30  through the aperture  37  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 . The receptacle  12  must be coupled securely to the wall  30  through the use of a coupling mechanism  22 .  
         [0049]     In one embodiment, shown in  FIGS. 3, 3A , and  3 B, the coupling mechanism  22  comprises an adhesive strip  50  comprising a tacky surface  52  and a removable backing strip  54 . In this embodiment, one first removes the removable backing strip  54  prior to insertion of the closed end  16  of the receptacle  12  into the wall  30 . The interior surface of the trim  20  is then pressed firmly against the outer surface  32  of the wall  30  until a secure coupling of the receptacle  12  to the wall  30  exists.  
         [0050]     In another embodiment, shown in  FIGS. 1 and 1 A, the coupling mechanism  22  comprises at least one screw  42  that is inserted through the trim  20  and into the wall  30  after the closed end  16  of the receptacle  12  has been inserted into the wall  30  through the aperture  37 .  
         [0051]     In another embodiment, shown in  FIGS. 6, 6A  and  6 B, at least one screw  42  is inserted through a side portion of the receptacle  12  and into a wall stud after the closed end  16  of the receptacle  12  has been inserted into the wall. It should be clearly understood that the term screw  42  refers to a screw, a nail, or any other type of rod-shaped fastener designed to couple two objects together.  
         [0052]     In another embodiment, shown in  FIGS. 4 and 4 A, the receptacle  12  comprises a plurality of gripping arms  56 . In this way, once the closed end  16  of the receptacle  12  is fully inserted through the aperture  37  and into the interior space  34  of the wall  30 , the second end  60  of each gripping arm  56  will extend beyond the trim  20  and come into contact with an interior surface  35  of the wall  30  so as to securely couple the receptacle  12  to the wall  30  with the trim  20  proximate the outer surface  32  of the wall  30 .  
         [0053]     While, various methods for coupling the self-trimming in-wall receptacle  10  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 .  
         [0054]     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.