Patent Document

RELATED APPLICATIONS 
   This application is a continuation of U.S. patent application Ser. No. 10/435,716 filed May 8, 2003 now U.S. Pat. No. 7,118,413 and entitled QUICK ASSEMBLING ELECTRICAL CONNECTION BOX APPARATUS AND METHOD, which is a continuation of 09/974,306 filed Oct. 10, 2001, now U.S. Pat. No. 6,609,927 issued Aug. 26, 2003, which claims the benefit of U.S. Provisional Patent Application Ser. No. 60/297,823 filed Jun. 12, 2001 and U.S. Provisional Patent Application Ser. No. 60/273,803 filed on Mar. 6, 2001. 

   BACKGROUND 
   1. The Field of the Invention 
   This invention relates to fixture anchoring and, more particularly, to novel systems and methods for facilitating connection box assembly. 
   2. The Background Art 
   Manually installing screws or other fasteners is often time consuming. Additionally, in certain installations, the installer must employ his or her hands to hold several components as well as rotate a tool transferring rotation to a screw or other type of fastener. Maintaining all of the components in proper alignment is often difficult and requires skill. In any case, the complexity slows the installation process. 
   Power tools may simplify the installation process by providing the motion (e.g. rotation) necessary to advance or install a fastener. The power tool must, however, be held and positioned in a manner similar to a manual tool. Thus, the use of power tools may not significantly lessen the demands on the installer. 
   An electrical connection box assembly is one example of a time consuming fastener installation. Once an electrical fixture has been wired, the fixture is typically secured inside a connection box. Securement of the electrical fixture to the connection box often involves the installation of multiple screws. These screws are generally over an inch long and are relatively finely threaded. The length of the screws may be selected to accommodate various connection box placements and wall paneling thicknesses. To complete a conventional electrical connection box assembly, a face plate is secured to the fixture by another screw. Similar problems may be encountered in the installation of connections boxes used for a wide variety of devices and systems, including without limitation telephone, stereo, computer network, information systems, cable television system, and security systems fixtures. 
   The installation of the connection box screws requires an installer concurrently to hold a fixture, maintain screw alignment, and provide rotation to the screw. Often it is difficult to initiate engagement between the screw and the receiving hole. Such difficulty typically arises because the receiving hole may be obscured by the wall paneling or recessed into the wall. Once the screw is in engagement with the receiving hole, the time consuming and often laborious task of advancing the finely threaded screw remains. 
   Face plate screws and other securement devices may be unsightly as well as time consuming and laborious to install. Screws used to secure face plates to connection boxes and fixtures are typically painted and are, therefore, exposed to chipping, tarnishing, wear, and oxidation. In certain applications, it may be desirable to use a snap-on face plate to provide fast securement without the use of screws to provide securement. 
   Fixture installation may consume a large portion of an electrician&#39;s time budget for any given project. If the amount of time needed to install electrical fixtures were reduced, both the installer and the financier (e.g. home owner, developer, or the like) may realize large economic rewards. 
   Attempts have been made to provide quick assembling connection boxes and fixture assemblies. Quick assembling devices typically involve at least some rotation of the fixture screws and, therefore, require the use of tools for installation. Often these devices are limited in how well they are able to engage the threads of the fixture screws. Thus, such devices may not provide a reliable and solid securement between the fixture and connection box. 
   Typical screwless face plates require additional components to enable securement to the electrical fixture. These additional components increase manufacturing cost as well as installation time. 
   What is needed is an anchor that provides a strong and reliable securement between a fixture and associated connection box. Such an anchor would also provide for quick and simple installation thereof. Additionally, a screwless face plate that requires no additional components to accomplish a reliable securement would be an advancement in the art. Such a connection box assembly would greatly reduce the time, skill level, and effort required to assemble and complete connection box installation (e.g. electrical fixture installation or the like). 
   BRIEF SUMMARY AND OBJECTS OF THE INVENTION 
   In view of the foregoing, it is a primary object of the present invention to provide an apparatus and method requiring minimal time, effort, and skill to install. 
   It is a further object of the invention to provide a connection box apparatus and method that may be installed without screw rotation. 
   Consistent with the foregoing objects, and in accordance with the invention as embodied and broadly described herein, a method and apparatus are disclosed. An embodiment in accordance with the present invention may provide an apparatus for securing a fixture to a connection box. In a factory manufacturing process an anchor may be secured to a fixture. In one embodiment, the anchor is secured to the fixture by a releasable fastener. The anchor may have an engagement mechanism formed therewith. 
   A connection box may be provided to house lines or wires originiating from a signal source to terminate therein. The lines may provide a connection for the fixture. A receiver may be associated with the connection box. The receiver may have an engagement mechanism formed to receive and retain the engagement mechanism of the anchor. Thus, the anchor and receiver may be intermediaries in the securement of the fixture to the connection box. 
   In certain applications, screws and other securement devices may be unsightly. In these applications it may be desirable to provide a snap-on face plate to provide fast securement without the use of screws. Face plates are often secured to fixtures to cover and hide the wiring and access holes therebehind. Face plates in accordance with the present invention may have engagement prongs. These prongs may be inserted through apertures in a corresponding fixture to maintain the face plate aligned securely thereagainst. 
   In selected embodiments in accordance with the present invention, an installer may first connect a fixture to the lines or wires housed in a connection box. A face plate may be installed by simply pressing the engagement prongs through the apropriate apertures in the fixture. Once a fixture has been connected to the lines and a face plate applied, the fixture may be secured to the connection box by inserting one or more of the attached anchors into corresponding receivers associated with the connection box. The anchors may be inserted a selected distance into the receivers until the face plate is properly positioned. Insertion of an anchor into a receiver may be accomplished without the aid of tools. 
   The method of engagement between the engagement mechanism of the receiver and that of the anchor may be selected to provide a fast, clean securement. In selected embodiments, the engagement mechanism of the receiver may be a barb configured to engage a series of teeth provided as part of the engagement mechanism of the anchor. In other embodiments, the engagement mechanism of the anchor may be a barb configured to engage a series of teeth provided as part of the engagement mechanism of the receiver. The engagement between the anchor and receiver may provide a single or multiple locking positions. 
   By applying embodiments in accordance with the present invention, a fixture may be secured to a connection box in a comparatively short amount of time. Embodiments in accordance with the present invention may be particularly advantageous when it is desirable to preserve the ability to remove the fixture from the connection box. For example, an electrician or computer network technician may need to remove a fixture to gain access to the lines or wiring tucked therebehind. In such a situation, the face plate may be “popped” off and the fasteners holding the fixture to the anchors may be released, thus freeing the fixture. Each anchor may maintain engagement with its corresponding receiver. After the revisions are complete the fixture may once again be secured to the anchors by the installation of the fastener previously released. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The foregoing and other objects and features of the present invention will become more fully apparent from the following description, taken in conjunction with the accompanying drawings. Understanding that these drawings depict only typical embodiments of the invention and are, therefore, not to be considered limiting of its scope, the invention will be described with additional specificity and detail through use of the accompanying drawings in which: 
       FIG. 1  is an exploded perspective view of a connection box assembly in accordance with the present invention; 
       FIG. 2  is a perspective view of one embodiment of an anchor in accordance with the present invention; 
       FIG. 3  is a perspective view of an alternative embodiment of an anchor in accordance with the present invention; 
       FIG. 4  is a perspective view of another alternative embodiment of an anchor in accordance with the present invention; 
       FIG. 5  is a top cross-sectional view of an engagement between an anchor and receiver in accordance with the present invention; 
       FIG. 6  is a front cross-sectional view of the engagement of  FIG. 5 ; 
       FIG. 7  is a partial perspective view of an alternative embodiment of an anchor in accordance with the present invention; 
       FIG. 8  is a top cross-sectional view of an alternative engagement between an anchor and receiver in accordance with the present invention; 
       FIG. 9  is a top cross-sectional view of another alternative engagement between an anchor and receiver in accordance with the present invention; 
       FIG. 10  is a partial cutaway, perspective view of an application of a quick assembling connection box in accordance with the present invention; 
       FIG. 11  is a perspective view of a receiver in accordance with the present invention formed as part of a metal connection box; 
       FIG. 12  is an exploded perspective view of an alternative embodiment of a face plate and fixture assembly in accordance with the present invention; 
       FIG. 13  is a perspective view of a complete assembly prepared for installation in accordance with the present invention; 
       FIG. 14  is a partial perspective view of a face plate and fixture assembly in accordance with the present invention; 
       FIG. 15  is a side cross-sectional view of a screwless face plate assembly using an adapter in accordance with the present invention; 
       FIG. 16  is a side cross-sectional view of an engagement prong in accordance with the present invention; 
       FIG. 17  is a perspective view of an engagement prong in accordance with the present invention; 
       FIG. 18  is a perspective view of a fixture with a flange modified in accordance with the present invention; 
       FIG. 19  is a perspective view of an alternative embodiment of a screwless face plate in accordance with the present invention to engage the fixture of  FIG. 18 ; 
       FIG. 20  is a side cross-sectional view of an engagement between the fixture of  FIG. 18  and the screwless face plate of  FIG. 19 ; 
       FIG. 21  is a partial perspective view of alternative engagement between a screwless face plate and an fixture in accordance with the present invention; 
       FIG. 22  is a cutaway, partial perspective view of alternative engagement between a screwless face plate and a fixture in accordance with the present invention; 
       FIG. 23  is a perspective view of a fixture with an adapter in accordance with the present invention; and 
       FIG. 24  is a side cross-sectional view of a fixture with an adapter in accordance with the present invention. 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   It will be readily understood that the connection box assemblies of the present invention, as generally described and illustrated in the Figures herein, could be arranged and designed in a wide variety of different configurations. Thus, the description herein is not intended to limit the scope of the invention, but is merely representative of certain presently preferred embodiments of devices and systems in accordance with the invention. Those of ordinary skill in the art will, of course, appreciate that various modifications to the details herein may easily be made without departing from the essential characteristics of the invention, as described. Thus, the following information is intended only by way of example, and simply illustrates certain presently preferred embodiments consistent with the invention. 
   Referring to  FIG. 1 , in discussing the Figures, it may be advantageous to establish a reliable coordinate system to aid in the description of several of the embodiments in accordance with the present invention. Coordinate axes  11  may be defined by longitudinal  11   a , lateral  11   b , and transverse directions  11   c  substantially orthogonal to one another. 
   A connection box assembly  10  in accordance with the present invention may provide an apparatus for securing a fixture  12  to a connection box  14 . In a factory manufacturing process, an anchor  16  may be secured to the fixture  12 . The connection box  14  to which the fixture  12  is to be secured may have a receiver  18  associated therewith for admitting and retaining the anchor  16 . Thus, the anchor  16  and receiver  18  may be intermediaries in the securement of the fixture  12  to the connection box  14 . A face plate  20  may be provided to cover and hide the wiring and access holes therebehind. 
   A fixture  12  may be any suitable piece for which securement is desired. For example, a fixture  12  may be a power receptacle, power switch, light fixture, telephone jack, network jack, cable connector, stereo system connector, information system connector, or any other unit  12  for which permanent or removable securement to a connection box  14  may be desired. In a similar manner, the connection box  14  may be any box to which a fixture  12  may be secured. A connection box  14  may be constructed of any suitable material. Suitable materials may include without limitation metals, polymers, composites, and the like. Additionally, a connection box  14 , in accordance with the present invention, may be of any suitable size. For example, a connection box  14  may be a single gang, double gang, triple gang, quadruple gang, quintuple gang, or the like. The concepts presented herein are illustrated as a single gang box, however, the principles and concepts may easily be expanded to multiple-gang connection boxes. 
   Embodiments in accordance with the present invention may be particularly well suited to assemblies that may be assembled in the field (i.e. not in a factory). Such field assemblies need not be limited to connection box assemblies  10 . Embodiments in accordance with the present invention may provide convenience and ease of assembly in the field where less than perfect conditions are often encountered. 
   An anchor  16  in accordance with the present invention may be constructed, formed, machined, extruded, molded, cast, or otherwise made from any suitable material. Suitable materials may include without limitation metals, polymers, composites, or the like. For example, in certain embodiments, an anchor  16  may be formed of a polymer in a molding process. 
   An anchor  16  may be secured to a fixture  12  in any suitable manner. In certain embodiments, an anchor  16  may be secured to a fixture  12  by a fastener  22  such as a bolt, rivet, screw, engagement prong, engagement hook, or the like. In other embodiments, an anchor  16  may be glued or otherwise bonded to a fixture  12 . Additionally, an anchor  16  may be formed as an integral part of the fixture  12 . 
   Each form of attachment between the anchor  16  and the fixture  12  may have particular advantages. In certain applications, such as the installation of power receptacles  12 , switches  12 , computer network outlets  12 , cable television outlets  12 , and the like an installer may need to remove a fixture  12  to gain access to something (e.g. wiring) tucked therebehind. In such a situation, screws  22  may provide an ideal attachment between the anchor  16  and the fixture  12 . The screws  22  may be removed, thus freeing the fixture  12 . The anchors  16  may maintain engagement with the connection box  14 . After the revisions are complete the fixture  12  may once again be secured to the anchors  16  by the insertion of the screws  22  previously removed. 
   In selected applications, multiple points of securement between a fixture  12  and a connection box  14  may exist. In such situations, an anchor  16  in accordance with the present invention may be applied to all or a subset of the securement locations. For example, power receptacles  12  and switches  12  are typically secured to connection boxes  14  by two screws spaced from each other in a longitudinal direction  11   a . An anchor  16   a ,  16   b  may be applied to fasteners  22   a ,  22   b  respectively. Similarly, a connection box  14  may have multiple receivers  18   a ,  18   b  to engage both anchors  16   a ,  16   b , respectively. 
   The method of engagement between a receiver  18  and an anchor  14  may be selected to provide a fast, clean securement. By so doing, the fixture  12  may be secured to the connection box  14  in a minimum amount of time. For example, installers (e.g. electricians, network technicians, cable television installers, and the like) spend a large portion of their installation time screwing fixtures  12  to connection boxes  14 . In certain embodiments in accordance with the present invention, a fastener  22  (e.g. screw  22 ) may be introduced to secure an anchor  16  to the appropriate locations on a fixture  12  by a manufacturing machine. Thus, the installation of the fastener  22  may be performed in ideal conditions with proper alignment and fast tool speeds. In the field, when an installer installs the fixture  12 , the time consuming screw installation no longer needs to be performed. An anchor  16  may simply be inserted into a receiver  18 . 
   The embodiments of the fixture  12 , connection box  14 , anchors  16   a ,  16   b , receivers  18   a ,  18   b , and face plate  20 , as illustrated in  FIG. 1  may be arranged and designed in a wide variety of different configurations that fall within the scope of the present invention. Thus, the description hereinabove is not intended to limit the scope of the possible embodiments, but is merely representative of certain presently preferred embodiments of devices and systems in accordance with the invention. The information is intended only by way of example. 
   Referring to  FIG. 2 , an anchor  16  in accordance with the present invention may have an engagement mechanism  24  configured to provide a mechanical grip with a receiver  18 . If an anchor  16  is to be secured to a fixture  12  by a bolt  22  or screw  22 , a threaded aperture  26  may be formed therein. The threaded aperture  26  may extend completely or only partially through the anchor  16  in a transverse direction  11   c.    
   A length  28  of the engagement mechanism  24  may be selected to provide a desired number of engagement locations  30 . In selected embodiments, each engagement location  30  is a tooth  30 . Additionally, the engagement length  28  and the number of engagement locations  30  may be selected to permit insertion of the anchor  16  a desired distance into the receiver  18 . Thus, providing a desired alignment of the fixture  12  with respect to the connection box  14 . 
   In selected embodiments, an anchor  14  in accordance with the present invention may include a spacer  32 . The length  34  of the spacer  32  may be selected to provide additional control over the spacing of the fixture  12  in relation to the connection box  14 . 
   In certain embodiments, one end  36  of the anchor  16  may be formed to promote easy insertion into the receiver  18 . For example, an end  36  may be pointed, rounded, tapered, or otherwise formed. 
   An anchor  16  in accordance with the present invention may have any suitable cross-section. For example, the cross-section may be rectangular, circular, triangular, oval, an unconventional shape, or the like. The cross-sectional shape of an anchor  16  may be selected to resist rotation about a transverse axis  11   c  once installed inside a receiver  18 . For example, an anchor  16  having a generally circular cross-section may have a key-way formed therein to correspond to a key formed or located in the receiver  18 . 
   The shape and configuration of a receiver  18  may be selected to match and complement the particular shape of a selected anchor  16 . For example, if an anchor  16  having a rectangular cross section is desired, the receiver  18  may be formed to have a generally rectangular shape. Thus, the receiver  18  may admit the anchor  16  and hold the anchor  16  securely without motion (e.g rotation about a transverse axis  11   c ) therebetween. 
   Referring to  FIG. 3 , in certain embodiments, an anchor  16  may have multiple sliding surfaces  38  to promote ease of insertion and proper alignment. A recessed groove  40  may be formed in one or more surfaces  38  of the anchor  16  to provide a location for disposition of an engagement mechanism  24 . Such an engagement mechanism  24  may be recessed to reduce the risk of interfering with proper insertion of the anchor  16  into the receiver  18 . 
   Referring to  FIG. 4 , an anchor  16  may have a generally circular cross-section. In such an embodiment, the anchor may include a single flat  42  or may include a plurality of flats  42  that provide a location for disposition of an engagement mechanism  24 . The flats  42  may also provide a location for a corresponding receiver  18  to engage the anchor  16  to resist rotation about a transverse axis  11   c.    
     FIG. 4  also illustrates an alternative embodiment of a fastener  22  in accordance with the present invention. Opposing engagement hooks  22  may be shaped to promote insertion into a corresponding aperture in a fixture  12 . The engagement hooks  22  may be formed to engage an aperture of any suitable shape (e.g. circular, oval, triangular, or the like). The illustrated engagement hooks  22  have been formed in a shape to fit a square aperture. A square aperture may provide a mechanism to resist rotation of the anchor  16  about a transverse axis  11   c  with respect to a corresponding fixture  12 . Engagement hooks  22  in accordance with the present invention may flex to allow an anchor  16  to be separated from the fixture  12  to which the anchor  16  is attached. Once separated, the anchor  16  and fixture  12  may be reattached by reinserting the engagement hooks  22  of the anchor  16  through the corresponding aperture in the fixture  12 . 
   The embodiments of anchors  16 , as illustrated in  FIGS. 2-4  could be arranged and designed in a wide variety of different configurations that fall within the scope of the present invention. Thus, the description hereinabove is not intended to limit the scope of the possible embodiments, but is merely representative of certain presently preferred embodiments of devices and systems in accordance with the invention. The information is intended only by way of example and not by way of limitation. 
   Referring to  FIGS. 5-6  while continuing to refer generally to  FIGS. 1-4 , as discussed hereinabove, an anchor  16  in accordance with the present invention may have multiple sliding surfaces  38 . The sliding surfaces  38  may maintain proper alignment of the anchor  16  with respect to the receiver  18 . 
   In selected embodiments, a receiver  18  in accordance with the present invention may include an engagement mechanism  39 . This engagement mechanism  39  may be configured to engage the engagement mechanism  24  of an anchor  16 . In selected embodiments, an engagement mechanism  39  may comprise hooks  44  or barbs  44 . These barbs  44  may extend from the receiver  18  with a shape selected to engage the teeth  30  of the anchor  16 . The engagement of the hooks  44  and teeth  30  may be selected to provide unidirectional motion so that an anchor  16  may be easily inserted yet resist removal in a transverse direction  11   c . The number of teeth  30  and the incremental distance  46  therebetween may be selected to provide a continuum of possible locking positions between the anchor  16  and the receiver  18 . 
   Referring to  FIGS. 7-8  while continuing to refer generally to  FIGS. 1-6 , in an alternative embodiment, an anchor  16  may include a single hook  44 . In selected embodiments, an anchor  16  may include multiple hooks  44 . A flexible region  48  may permit a hook  44  to flex as it “clicks” or passes over the teeth  30  of a receiver  18 . As discussed hereinabove and as best shown in  FIG. 8 , the number of teeth  30  and the incremental distance  46  therebetween may be selected to provide a continuum of possible locking positions between the anchor  16  and the receiver  18 . 
   Referring to  FIG. 9 , in selected embodiments, the engagement between an anchor  16  and a receiver  18  may not be incremental, rather a single locking position may be defined. In such an embodiment, the anchor  16  may be inserted into the receiver  18  until a lock  50  is activated. In selected embodiments, a lock  50  may consist of a hook  44  secured on the distal end of a flexible region  48 . A stop  52  may provide a register to correctly position the anchor  16  with respect to the receiver  18 . When the anchor  16  is inserted to the stop  52 , a hook  44  may engage an engagement location  30  of the receiver  18 . 
   Referring to  FIG. 10 , the length  28  (see  FIG. 2 ) of the engagement mechanism  24  may be selected to best match the particular application to which the engagement mechanism  24  may be applied. For example, the installation of a light fixture  12  may be simplified by employing a comparatively long anchor  16  having a similarly long engagement mechanism  24 . In such an application, two long anchors  16  may be secured to the fixture  12 . The anchors  16  may be introduced into the corresponding receivers  18  a distance sufficient to engage the engagement mechanisms  39  thereof. The anchors  16  may then hold the fixture  12  in place while the installer proceeds to connect the necessary wires  54 . Upon completion of the connecting of the wires  54 , the fixture  12  may be pushed in a transverse direction  11   c  until a proper position is achieved. Thus, the installer need not hold the fixture  12  while connecting wires  54  and tightening terminal screws  56 . 
   Referring to  FIG. 11 , a receiver  18  may be associated with a connection box  14  in any suitable manner. In selected embodiments, the receiver  18  may be formed as an integral part of the connection box  14 . This forming may be part of a molding process. That is, the receiver  18  may be molded as part of the connection box  14  in its original forming process.  FIG. 11  illustrates an embodiment in which the receiver  18  is formed by stamping selected shapes from a metal connection box  14  and then bending the cut portions in a selected direction to form a guide  57  and an engagement mechanism  39 . In an alternative embodiment, a receiver  18  may be formed (e.g. molded, extruded, cast, machined, stamped, or the like) and then joined to the connection box  14 . Such a joining may be accomplished by bolting, screwing, welding, gluing, bonding, or the like. 
   Referring to  FIG. 12 , connection boxes  14  are typically installed and wired before the installation of the wall paneling (e.g., ceiling paneling and the like). Fixtures  12  and face plates  20  are typically installed after the installation of the wall paneling. The installation of wall paneling often involves the application of dry wall compound. It is very common for clumps of dry wall compound to be inadvertently introduced inside a previously installed connection box  14 . Receivers  18  in accordance with the present invention may be formed in a manner to greatly limit the adverse effects of misplaced dry wall compound. 
   For example, if dry wall compound were placed in the receiver entrance  58 , the receiver may be formed to have an open back exit  59 . Thus, anchor  16  may be inserted into the receiver  18  and any clump of dry wall compound may simply be pushed out the back  59  of the receiver  18 . The back  59  may be open to the exterior of the connection box  14 . The back  59  may also be configured to open to the interior of the connection box  14 . In such a configuration, a dry wall compound clump will be pushed to the interior of the connection box  14  where it can do no harm. 
   Embodiments in accordance with the present invention may be applied to any unit  12  for which permanent or removable securement to a connection box  14  is desired. Data terminals such as phone jacks, network jacks, cable connections, and the like may not have a fixture  12  associated therewith. These applications may deliver a transmission line to a jack  60  or connector  60  mounted directly in a face plate  20 . The face plate  20  provides the structure and support for the jack  60 , and indeed may provide many of the same functions as a fixture  12 . Typically these face plates have been secured directly to a corresponding connection box by multiple screws. Installation of such screws presents difficulties similar to those encountered in the installation of fixtures  12 . 
     FIG. 12  illustrates one embodiment of a jack connection box assembly  10  in accordance with the present invention. Interface members  62   a ,  62   b  may provide an interface between a face plate  20  and anchors  16   a ,  16   b . In selected embodiments, the interface members  62  may include an aperture  64  to accommodate securement of an anchor  16 . Additional apertures  66  may provide locations for the face plate  20  to engage the interface members  62 . In certain embodiments, extensions  68  or “dog ears”  68  may be incorporated to hold each interface member  62  flush with the wall paneling. 
   The interface members  62  may be formed in any suitable shape for providing adequate engagement between an anchor  16  and a face plate  20 . In one embodiment, the interface members  62  are generally flat pieces having multiple apertures  64 ,  66  and extensions  68 . The interface members  62  may be constructed of any suitable material. In selected embodiments, interface members  62  may be formed by stamping sheet metal. In alternative embodiments, interface members  62  may be molded from a polymer, a composite, or the like. 
   Referring to  FIGS. 13-15 , as discussed hereinabove, after the installation of a fixture  12 , a face plate  20  is typically secured thereto to hide the under workings from view. Conventional face plates  20  are often secured by at least one screw. Screws and other securement devices may be unsightly. Screws used to secure face plates  20  to receptacles and switches are typically painted and are, therefore, exposed to chipping, tarnishing, wear, oxidation, and the like. In such applications, it may be desirable to provide a snap-on assembly to provide fast securement of a face plate  20  without the use of screws. 
     FIGS. 13-15  illustrate one embodiment of a screwless face plate  20  in accordance with the present invention. In selected embodiments, a face plate  20  may include engagement prongs  70 . The engagement prongs  70  may engage a fixture  12  and maintain the face plate  20  aligned and secured thereto. Thus, once a face plate  20  has been attached, a complete fixture  12  assembly may be quickly and easily wired and then secured to a corresponding connection box  14 . 
   Selected fixtures  12  in accordance with the present invention may include flanges  72 . Flanges  72   a ,  72   b  may extend away from a main body  74  of a fixture  12  in a longitudinal direction  11   a . In selected embodiments, the flanges  72  may include an aperture  64  to accommodate the securement of an anchor  16 . Additional apertures  66  may provide locations for the engagement prongs  70  of the face plate  20  to engage the flanges  72 . In certain embodiments, extensions  68  or “dog ears”  68  may be selected to hold the fixture  12  flush with the wall paneling. 
   Engagement prongs  70  in accordance with the present invention may be formed to have multiple hooks  76   a ,  76   b ,  76   c ,  76   d . The hooks  76  may be secured to the face plate  20  by flexible necks  78   a ,  78   b ,  78   c ,  78   d , respectively. A flex clearance  80  may be provided between the hooks  76  so that as the prong  70  is inserted through an aperture  66 , the hooks  76  may deflect toward each other, thus, effectively reducing the diameter of the prong  70 . Once the prong  70  has passed through the aperture  66 , the hooks  76  may return to their neutral position and engage the edges of the aperture  66 . 
   Referring to  FIGS. 16 and 17 , in selected embodiments, the hooks  76  may be shaped to release at a desired removal loading, thus, once the face plate  20  is removed, the face plate  20  may be used again. For example, the hooks  76  may be provided with an inside taper  82 . The inside taper  82  may allow each hook  76  to gradually flex and bend towards the flex clearance  80  as the face plate  20  is pulled away from the fixture  12  so that the effective diameter of the engagement prong  70  may be reduced and the prong  70  may be removed from the aperture  66 . In an alternative embodiment, a face plate  20  in accordance with the present invention may be removed by applying sufficient force to fail the hooks  66 . 
   A screwless face plate  20  in accordance with the present invention may be formed of any suitable material. This material may be selected based on several characteristics including cost, aesthetics, dielectric constant, thermal capacity, strength, toughness, flexibility, formability, and the like. 
   Engagement prongs  70  in accordance with the present invention may have any suitable configuration. The number of prongs  70  may range from one to several and be selected to provide a balanced securement between a face plate  20  and a fixture  12 . The number of hooks  76  making up each prong  70  may also range from one to several depending on a desired engagement strength, ease of manufacture, ease of installation, ease of removal, and the like. In certain embodiments, the engagement strength may be balanced with a desired release loading. The general shape or contour of the prongs  70  may also be selected to provide a desired engagement strength, ease of manufacture, ease of installation, ease of removal, and the like. 
   Referring to  FIGS. 18-20 , alternative embodiments in accordance with the present invention may employ alternative methods for securing a screwless face plate  20  to a fixture  12 . In one alternative embodiment, a flange  72   a  of a fixture  12  may have an engagement lip  84  formed therein. A extension  86  may be formed in association with a corresponding face plate  20 . The engagement lip  84  may be configured to fit behind the extension  86  to hold the upper portion of the face plate  20  to the flange  72   a.    
   An aperture  66  may be formed in a flange  72   b  of the fixture  12 . A corresponding engagement prong  70  may be formed in association with the face plate  20 . The prong  70  illustrated in  FIGS. 18-19  is an example of a single hook, rectangular prong  70 . The aperture  66  may be shaped to correspond to the design of the prong  70 . In selected embodiments, the lip  84 /extension  86  and aperture  66 /prong  70  combinations may cooperate to secure the face plate  20  to the fixture  12 . Such an embodiment may be installed by first inserting the lip  84  behind the extension  86  and then rotating the face plate  20  down against the fixture  12  until the prong(s)  70  may be inserted into the corresponding aperture(s)  66 . The prong  70  engagement may provide a tie to resist the tendency of the lip  84  to disengage from the extension  86 . 
   An engagement lip  84  in accordance with the present invention may be divided into multiple engagement lips  84 . In selected embodiments, an upper flange  72   a  may be formed into two lips  84   a ,  84   b . The lips  84   a ,  84   b  may be separated by a notch  88 . A stop  90  may be formed as part of a corresponding extension  86 . The stop  90  may fit into the notch  88  to prevent lateral motion between the upper flange  72   a  and the face plate  20 . 
   In certain embodiments, ends  92  may form an enclosure  94  in combination with an extension  86  and corresponding face plate  20 . The ends  92  may function to laterally retain the lip  84  of a flange  72   a , when assembled. 
   In selected embodiments, a face plate  20  in accordance with the present invention may have an access notch  96 . In certain embodiments, an access notch  96  may simply provide a hold to permit the application of force to “pop” a face plate  20  from a corresponding fixture  12 . In alternative embodiments, the access notch  96  may provide access behind the face plate  20  to a slender tool. The slender tool may then be used to assist in the release of an engagement prong  70 . 
   Referring to  FIG. 21 , an alternative embodiment of an engagement between a screwless face plate  20  and a fixture  12  may involve the engagement of an edge  98  of the flanges  72  of the fixture  12 . One or more of the engagement prongs  70  of the face plate  20  may be configured to engage an edge  98 . In selected embodiments, the prongs  70  may be formed to have a hook  76  and a flexible neck  78 . In certain embodiments, a flange  72  may include a formation  100  to resist motion in a longitudinal direction  11   a  of a face plate  70  with respect thereto. Such a formation  100  may be formed by bending, cutting and bending, notching, or similarly modifying the edge  98  to resist sliding of a prong  70  therealong in a longitudinal direction  11   a.    
   Referring to  FIG. 22 , an alternative embodiment of an engagement between a screwless face plate  20  and a fixture  12  may involve an engagement between a face plate  20  and an interface  104  of a fixture  12 . Typically, the interface  104  of a fixture  12  extends a selected distance  106  to provide a flush joint with a face plate  20 . That is, the interface  104  extends to provide a facing  108  that may be substantially coplanar with a surface  110  of the face plate  20 , thereby improving aesthetic appeal. The area of the facing  108  may be selected to correspond to a selected interface  104 . Power outlet plugs  104  provide a relatively large surface area. In contrast, switches  104  typically have a toggle central unit and a thin border providing minimal surrounding facing  108 . 
   The extension distance  106  of the electrical interface  104  provides the surface (substantially perpendicular to the facing  108 ) of an edge  102 . An edge  112  of an aperture  114  (the aperture  114  may admit the interface  104  through the face plate  20 ) may be configured to engage the edge  102  of the interface  104 . This engagement may be of any suitable form. For example, the engagement may involve any suitable combination of tabs, recesses, hooks, shoulders, and the like. 
   In selected embodiments, the engagement between the edges  102 ,  112  may involve tabs  116  formed on the face plate  20  and recesses  118  formed in the interface  104 . The shape, number, and location of these corresponding pairs may be selected to provide a desired engagement strength, magnitude, and balance. Engagement strength refers to the amount of force required to apply and secure the face plate  20  to the fixture  12  or, alternatively, the force required to separate the face plate  20  from the fixture  12 . The engagement strength may be selected to provide fast “snap-on” assembly without risking inadvertent removal of the face plate  20  and possible electrical shock resulting therefrom. 
   Referring to  FIGS. 23 and 24 , an adapter  120  may be provided to convert or retrofit a conventional fixture  12  to receive a screwless face plate  20 . In selected embodiments, an adapter  120  in accordance with the present invention may include an aperture  122  corresponding to aperture  64  of a flange  72 . A fastener  22  used to secure an anchor  16  to a fixture  12  may also pass through the aperture  122  to hold an adapter  120  in place against the flange  72 . The adapter  120  may extend to provide apertures  68  for admitting the prongs  70  of a corresponding face plate  20 . In this manner, a snap-on, screwless face plate  20  may be retrofitted to typical power receptacles and switches. 
   An adapter  120  in accordance with the present invention may be formed of any suitable material. In selected embodiments, the adapter  120  may be formed by stamping sheet metal. In an alternative embodiment, the adapter  120  may be a molded polymer or composite. 
   From the above discussion, it will be appreciated that the present invention provides an apparatus and method for fast and simple connection box assembly without screw rotation and the time associated therewith. An embodiment in accordance with the present invention may provide an apparatus for securing a fixture to a connection box. In a factory manufacturing process an anchor may be secured to a fixture. The anchor may have an engagement mechanism formed therewith. A connection box may be provided to house wires proceeding from a source to terminate therein. A receiver may be associated with the connection box. The receiver may have an engagement mechanism formed to receive and retain the engagement mechanism of the anchor. Thus, the anchor and receiver may be intermediaries in the securement of the fixture to the connection box. Face plates in accordance with the present invention may have engagement prongs. These prongs may be inserted through apertures in a corresponding fixture to maintain the face plate aligned securely thereagainst. A face plate may be installed by simply pressing the engagement prongs through the appropriate apertures in the fixture. Once a fixture has been wired and a face plate applied thereto, the resulting assembly may be secured to the connection box by inserting one or more of the attached anchors into corresponding receivers associated with the connection box. The anchor may be inserted a depth into the receiver selected to properly position the face plate. Insertion of an anchor into a receiver may be accomplished without the aid of tools. 
   The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative, and not restrictive. The scope of the invention is, therefore, indicated by the appended claims, rather than by the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope.

Technology Category: h