Patent Document

CROSS-REFERENCE TO RELATED APPLICATIONS 
     (Not Applicable) 
     STATEMENT RE: FEDERALLY SPONSORED RESEARCH/DEVELOPMENT 
     (Not Applicable) 
     BACKGROUND OF THE INVENTION 
     The present invention generally relates to wall-mounted audio controls and in particular to an audio control housing and a wall mountable receptacle for receiving the audio control and its housing. 
     Typically, in the past when installing home entertainment systems having audio controls mounted in the wall, a technician would turn an electrical box around and trace a cut-out on the wall. A plug would be removed from the sheetrock wall covering where marked, and the audio control would be installed in the opening. The audio control would then be cleated or otherwise screwed into the sheetrock wall covering. Over time, and due to frequent use of the audio control, the sheetrock would flake away and the audio control would become loose in the wall. 
     Since it is desirable to mount an audio control, near the speakers or equipment that are controlled thereby, the location of the wall mount may not always be the easiest for installation. When installing an audio control easiest for installation. When installing an audio control in an existing structure, versus new construction, extra care must be taken not to damage the wall; while at the same time mounting the control securely to the wall. The problem arises when trying to anchor a receptacle to a wall stud when the only access is an opening in the wall covering just large enough to receive the receptacle. Once installed, the audio control would be held in place merely by attachment to the wall covering, such as sheetrock. Over time and from frequent use, this too would cause the sheetrock to flake away and loosen. 
     Another problem with the prior art audio controls built for a wall mount is that there is potential damage from dust (e.g., sheetrock dust), fibers from wall insulation and dirt in general at a construction site. 
     Another prior art installation technique is to employ electrical junction boxes for housing the audio control. This normally works satisfactorily. However, it becomes more difficult when repairing or replacing the audio control. Moreover, it may be necessary to cut off the back of such junction boxes to fit certain audio control devices. 
     Accordingly, there is a need for an audio control and wall mount built expressly for supporting and housing an audio control. Moreover, there is a need for an audio control mount that allows easy removal and reinstallation for servicing or de-bugging a recently installed system. 
     BRIEF SUMMARY OF THE INVENTION 
     It is an object of the present invention to provide an improved audio control mounting for a wall, which audio control includes a modular receptacle therefor. 
     Another object of the present invention is to provide a wall-mount receptacle that allows for a quick and easy installation and screwless removal of an audio control. 
     Still another object of the present invention is to provide an improved housing for use in mounting an audio control module into walls of various thicknesses. 
     These and other objects, which will become apparent as the invention is described in detail below, are provided by an apparatus for housing an audio control and for securing the audio control to a wall. The apparatus includes a wall-mounted housing securable to a wall stud. The wall-mounted housing also includes a pair of cleats on an inner surface thereof. An audio control housing is provided for supporting the audio control and for engagement of the audio control to the wall-mounted housing. The audio control housing includes flex fingers with ridges formed thereon, wherein the ridges are operative to retractably engage the cleats to secure the audio control housing within the wall-mounted housing. 
     Another feature of the apparatus is that the ridges may be formed on the flex fingers and set at different spacing apart so that the audio control housing may be engagably received within the wall-mounted housing set at different depths. 
     Still another feature of the apparatus is that the wall-mounted housing may include a first set of horizontal ribs spaced equally along the inside walls thereof and the audio control housing may include a second set of horizontal ribs spaced to receive the first ribs so as to guide the audio control housing during insertion thereof into the wall-mounted housing. 
     Yet another feature of the apparatus is that the audio control housing may include a pair of grooves on the inside top and bottom thereof for receiving edges of a PC board component of the audio control module. Thus, the audio control module is securely held inside of the audio control housing. 
     Still other objects and features of the present invention will become readily apparent to those skilled in the art from the following detailed description, wherein is shown and described only the preferred embodiment of the invention, simply by way of illustration of the best mode contemplated of carrying out the invention. As will be realized, the invention is capable of other and different embodiments, and its several details are capable of modifications in various obvious respects, all without departing from the invention. Accordingly, the drawings and description are to be regarded as illustrative in nature, and not as restrictive, and what is intended to be protected by Letters Patent is set forth in the appended claims. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The general purpose of this invention, as well as a preferred mode of use, its objects and advantages will best be understood by reference to the following detailed description of an illustrative embodiment with reference to the accompanying drawings in which like reference numerals designate like parts throughout the figures thereof, wherein: 
     FIG. 1 is a perspective view of the audio control module mounted flush into a wall in accordance with the present invention. 
     FIG. 2 is a exploded view of the audio control module and receptacle therefor for mounting into a wall in accordance with the present invention. 
     FIG. 3 is an exploded view of the audio control module and receptacle therefor in accordance with the present invention. 
     FIGS. 4A,  4 B,  4 C and  4 D are perspective, top, front and side views, respectively, of the wall-mounted housing for receiving the audio control housing. 
     FIGS. 5A,  5 B,  5 C and  5 D are perspective, front, side and rear views, respectively, of the audio control housing. 
     FIGS. 6A,  6 B,  6 C and  6 D are perspective, front, side and rear views, respectively, of the audio control module. 
     FIGS. 7A,  7 B,  7 C and  7 D are perspective, top, front, and side views, respectively, of the audio control module mounted into the audio control housing. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring now to the drawings and to FIG. 1 in particular, an audio control module  10  according to the present invention is shown in a perspective view mounted into a wall  11  having a sheetrock covering  12 . However, it is pointed out that the present invention is also adaptable to other types of wall covering. In a new construction installation the module  10  is mounted into a housing  13 , which is affixed to a stud  14 . Details of the module  10  are shown in the exploded view of FIG. 2, wherein like reference numerals identify like parts. The audio control module  10  includes an audio control housing  15  that supports and protects the audio control  10 . The audio control  10  is further provided with a control knob  16  and a trace plate  17  to cover the module once mounted into the wall  12  by means of screws  18 . 
     The housing  13  (new construction housing) may be rigidly affixed to the stud  14  by means of a screw or nail  20  or the like in the manner usually employed in the construction industry for mounting electrical boxes in walls. The audio control housing  15  (retrofit housing) may include a pair of flex fingers  21  having ridges  21 A for securing it to the housing  13  by engagement of the ridges with cleats  22 . The housing  13  may include a pair of horizontal ribs  23 A and  23 B formed on each of the inside walls thereof. The audio control housing  15  includes a matching set of horizontal ribs  24 A and  24 B formed on each of the outer walls thereof such that the ribs  23 A and  23 B receive and engage the ribs  24 A and  24 B as the audio control housing is being inserted into the wall mounted housing  13 . 
     Referring now to FIG. 3, another exploded view of the audio control module  10  is shown in greater detail. Again like reference numerals identify like parts. In one embodiment the audio control  10  includes a PC board  40 , which is formed to slidably engage slots  41  and  42  of the audio control housing  15 . The flex fingers  21  (one on each side and only one is shown in the figure) are capable of bending inward of the housing  15  in order to clear the cleats  22  while inserting the module  15 . Once inserted, the installer releases the flex fingers  21  so that they may engage the cleats  22 . This secures the audio control housing  15 , and thus the audio control module  10  in the housing  13 . The ridges  21 A on the flex fingers  21  are spaced to match the thickness of the wall sheetrock covering. For example, ½″ is a standard thickness for most houses and ⅝″ is usually used for commercial buildings. The ridges on the flex fingers enable installation of the audio control  10  in these or other sheetrock thicknesses. 
     When installing the audio control  10  and housing into an existing wall (i.e., a retrofit installation), an opening may be formed in the wall covering  12  for receiving the outer rim of the housing  15 . The housing  15  is secured to the wall covering  12  by means of at least one translatable clamp  19  that is translatable after installation into a wall to engage the back (interior) side of the wall covering. The housing also includes four stop flanges  27  that engage the front (outer) side of the wall covering. Retrofit installations do not normally use the housing  13  because it is not feasible to attach it to the stud from the same small opening made in the wall covering. 
     Consequently, the present invention may be viewed as a combination of mateable housings; one suitable for new construction installations, and the other independently suitable for retrofit installations. Where a new construction installation is to take place, both housing are used. Where a retrofit installation is to take place, only the inner housing is used. A number of screws to be set in place is minimized and variations in wall thicknesses are easily accommodated by simply pushing the inner housing in place until the stop flanges  27  rest against the wall. This greatly simplifies the installation procedure, reduces installation time, and therefore allows an custom installer to reliably install multiple audio controllers throughout a house in a minimal period of time. The use of quick connect connecting blocks on the rear side of the inner module further simplifies the installation process. 
     Referring now to FIGS. 4A through 4D, perspective, top, front and side views, respectively, of the housing  13  are shown. The housing  13  is open in the back as distinguished from an electrical wiring box, which is closed. This enables distinction of the housing  13  from electrical boxes on a job site and aids in wiring of the module  10 . Brackets  25  and  26  are formed on the top and bottom of the housing  13  for receiving screws or nails to secure the housing to a wall stud. Also, in FIG. 4C both of the cleats  22  are clearly shown on the inner, front rim of the housing  13 . 
     Referring now to FIGS. 5A through 5D, perspective, front, side and rear views, respectively, of the inner housing  15  are shown. The flex fingers  21  and ridges  21 A are clearly shown in these figures. Stop flanges  27  may be placed at the four corners of the audio control housing  15  to prevent the housing from receding into the wall. That is, when the audio housing is inserted into the wall-mounted housing  13 , the stop flanges  27  abut against the wall surface and stop the inner housing from receding beyond a desired depth. When the audio control housing  15  is inserted at the desired depth, as determined by the stop flanges  27 , the flex fingers engage the cleats  22 . This holds the audio control housing  15 , with the module  10  secured therein, tautly in the wall-mounted housing  13 . Threaded screw holes  28  are formed in the top and bottom of the audio control housing  15  for securing the audio control module thereto. Moreover, with reference to FIG. 5D, the rear of the housing  15  maybe closed except for an opening  29  for the passing of low voltage wires (e.g., audio signal, power supply, control signals) to enter the audio control module  10 . 
     Referring now to FIGS. 6A through 6D, perspective, front, side and rear views, respectively, of the audio control module  10  are shown. A bracket  30  is attached to the front of the module  10  for use in securing the module to the audio control housing  15 . The bracket  30  extends beyond the top and bottom of the module and includes openings  31  and  32  for receiving screws that secure the module to the housing  15 . Electrical connections and other components (not shown) of the audio control are assembled onto the PC board  40 . 
     Referring now to FIGS. 7A through 7D, perspective, top, front and side views, respectively, of the module  10  inside the audio control housing  15  are shown. In FIGS.  7 C and  7 D: screws  34  and  35  may be seen, which screws secure the module  10  within the housing  15 . 
     Although the invention has been described with reference to a specific embodiment, this description is not meant to be construed in a limiting sense. Various modifications of the disclosed embodiment as well as alternative embodiments of the invention will become apparent to one skilled in the art upon reference to the description to the invention. It is therefore contemplated that the appended claims will cover any modifications of the embodiments that fall within the true scope of the invention.

Technology Category: 5