The present disclosure relates generally to installation of devices in residential and commercial structures, and more specifically to an in-wall and in-ceiling device mounting system.
In-wall and in-ceiling devices, such as in-wall and in-ceiling speakers, light fixtures, cameras, smoke and/or carbon monoxide detectors, etc. are becoming increasingly popular for residential and commercial applications. Such devices provide a number of benefits in contrast to free-standing and surface-mounted devices, as they do not consume floor space and generally provide an unobtrusive visual appearance. However, there are some shortcomings to existing in-wall and in-ceiling device mounting systems. Among other things, the installation procedure for existing in-wall and in-ceiling devices is typically time consuming and error prone. Such shortcomings are applicable to both retro-fit and new construction applications.
Consider the case of a retro-fit in-wall or in-ceiling speaker installation. In such a case, an installer (e.g., an audio/video (A/V) installer) may cut holes at selected location in existing wall or ceiling surface (e.g., drywall) and fish cables through the wall or ceiling. The installer than connects the cables, and installs the speakers directly into the cut holes. The speakers typically include a number of (e.g., 4) dog-leg mounting assemblies. The assemblies typically consist of a screw that extends through a flange of the speaker and a plastic or metal dog leg attached to the screw. When the screw is tightened, the dog leg swings from a retracted position to an extend position and tightens against the interior face of the wall or ceiling surface (e.g., drywall). Such tightening draws the flange against the exterior face of the wall or ceiling surface (e.g., drywall). Pinching action between the dog leg and flange holds the speaker in place.
However, such a mounting system has a number of shortcomings. The installer is required to utilize tools during the installation, for example, a screw driver or drill/driver to tighten the screws. If the installer over-tightens the screws, they may bend the flange of the speaker, hindering installation of speaker grilles, or damaging the wall or ceiling surface (e.g., drywall) the speaker is being installed into. If the installer under-tightens the screws, the speaker may not be well secured into the wall or ceiling. Should an installer be required to remove a speaker (for example, to change or check cable connections or for other purposes), the process may be finicky. Dog legs may not always swing back out of the way, hindering removal. Further, repeated installation and removal may cause damage to the wall or ceiling surface (e.g., drywall) because the dog legs and flange directly engage with its faces. If this damage extends beyond the portion concealed by the flange (and/or grille or faceplate), it may require patching to avoid an unsightly appearance. To simplify construction workflows, the installer may be tempted to install devices at an earlier stage of a construction project, when they are performing other tasks. Since repeated removal can cause damage to the wall or ceiling surface (e.g., drywall), they may further be tempted to leave the devices in place. Such early installation may render device internals more exposed to damage from dust, debris, impact, moisture, etc. present in ongoing work at the jobsite. These shortcomings are not limited to speakers. Similar issues are confronted with other types of retro-fit in-wall or in-ceiling device installations.
Next, consider the case of a new construction in-wall or in-ceiling speaker installation. An installer may run cabling and attach pre-construction brackets (also referred to a “rough-in brackets) to studs or joists before the wall or ceiling surface (e.g. drywall) is installed. A typical pre-construction bracket includes a mounting frame attached to a pair of mounting wings. The mounting frame is a relatively thin frame that serves as a template to cut the proper size hole for the intended speaker. The mounting wings are thin flanges (typically sheet metal) that extend on opposing sides of the mounting frame to span a joist or stud bay. The mounting wings are nailed or screwed to the joists or studs on either side of the bay to hold the mounting frame in a selected location. After the wall or ceiling surface (e.g., drywall) has been installed, and a hole cut based on the pre-construction bracket. The installer then connects the cables and installs the speaker into the cut hole. The speaker is typically similar to those used in retro-fit applications, and includes dog-leg mounting assemblies. However, in a new construction application, when the screws are tightened, the dog legs swing out and engage against the pre-construction bracket that is disposed on the interior face of the wall or ceiling surface (e.g., drywall), rather than the interior surface of the surface itself.
An installation using a pre-construction bracket still has a number of shortcomings. The installer is still required to use tools to install the speaker within the hole defined by the pre-construction bracket. Even though the dog-leg assemblies may engage the pre-construction bracket rather than the interior face of the wall or ceiling surface (e.g., drywall) itself, there still may be issues with over-tightening or under-tightening of screws, difficulties of removal, and potential damage to the surface. Again, these shortcomings are not limited to speakers. Similar issues are confronted with other types of new construction in-wall or in-ceiling device installations.
Accordingly, there is a need for a new in-wall and in-ceiling device mounting system that can address some or all of these shortcomings. It would be desirable if such a device mounting system were applicable to a wide range of devices, such as speakers, light fixtures, cameras, smoke and/or carbon monoxide detectors, etc., and were applicable to both retro-fit and new construction applications.
In one example embodiment, a device mounting system is provided for in-wall and/or in-ceiling use in residential and commercial structures, suitable for both retro-fit and new construction applications. The system includes a mounting ring that assists in mounting the device, and a device can (e.g., a speaker can, a light can, a camera can, a smoke and/or carbon monoxide detector can, etc.) that the includes device internals (e.g., an active or passive speaker, light fixture such as a flood, spot or wall washer, camera, smoke and/or carbon monoxide detector, etc.).
In an example installation, an installer installs the mounting ring at a first time, often at a relatively early stage of the project. In the case of a retro-fit, the mounting ring is installed into a hole cut at a selected location in an existing wall or ceiling surface (e.g., existing drywall). The mounting ring is retained by a mounting ring flange (e.g., made of a ferromagnetic metal such as steel) that engages the exterior face of the wall or ceiling (e.g., the exterior face of the drywall), and a number of (e.g., 4) spring clips affixed to the mounting ring body that engage the interior surface of wall or ceiling (e.g., the interior surface of the drywall). Pinching action created by the spring clips holds the mounting ring in place.
In the case of a new construction application, a pre-construction bracket, that includes a pre-construction bracket body and wings, is installed prior to the wall or ceiling surface (e.g., the drywall) being added installed. The pre-construction bracket is retained by attachment of the wings by fasteners (e.g., nails) to studs or joists. The pre-construction bracket may be used as a guide to cut a hole in the surface (e.g., cut the drywall) of the wall or ceiling, or, for a flush-mount installation, may be used with a mud housing and mud ring to which plaster or compound may be applied, thereby defining the hole. A mounting ring is installed into the hole defined by the pre-construction bracket and is retained similar to as in a retro-fit application by a number of (e.g., 4) spring clips.
Typically, the device can is installed at a second time, at a relatively late stage of the project. The device can is inserted into the mounting ring and retained therein by a combination of a number of (e.g., 4) magnets that are attracted to the mounting ring flange and a number of (e.g., 4) additional spring clips that engage an inner surface of the mounting ring body. In some cases, a grille or faceplate may and applied once the device can is in place, to provide a finished appearance.
Such a device mounting system may have a number of advantages. The installation of the mounting ring into the hole in the wall or ceiling surface (e.g., drywall) or pre-construction bracket, and the installation of the device can into the mounting ring, may be tool-less (i.e. may not require use of a screw-driver, drill/driver, hammer or other hand or power tools). Accordingly, issues of over tightening or under-tightening screws, and potential damage or lack of secure mounting caused thereby, may be avoided. Further, the entire device can (which holds the device internals) may be easily, and even repeatedly, removed from the wall or ceiling, without damage to the surface of the wall or ceiling (e.g., without damage to the drywall). Still further, work tasks may be performed at more optimal times in a project workflow. For example, installation of device can (which holds the device internals) may be reserved to a late stage of the project. This may minimize the risk of damage from dust, debris, impact, moisture, etc. to potentially sensitive device internals.
It should be understood that a variety of additional features and alternative embodiments may be implemented other than those discussed in this Summary. This Summary is intended simply as a brief introduction to the reader, and does not indicate or imply that the examples mentioned herein cover all aspects of the disclosure, or are necessary or essential aspects of the disclosure.
The description below refers to the accompanying drawings of example embodiments, of which:
Referring to
In a typical installation, an installer installs the mounting ring 110 at a first time (often at a relatively early stage of the project). In a retro-fit application, the mounting ring 110 may installed when cabling is being fished, but new components (e.g., A/V components) are not yet installed. The installer cuts a hole at a selected location in a wall or ceiling surface (e.g., in the drywall) having a diameter slightly larger than the cross section of the mounting ring body 130. The hole may be cut freehand or with the aid of a template or other guide. The mounting ring body 130 is then inserted therein. During insertion, the spring clips 140 are pressed back against the mounting ring body 130, but then spring back once within the wall or ceiling cavity. The mounting ring 110 is pressed snugly into the wall or ceiling, such that the spring clips 140 slide through their range of motion, so that the back-bent portions 145 engage the interior face of the wall or ceiling surface (e.g., the interior face of the drywall). The mounting ring flange 135 engages the exterior face of the wall or ceiling surface (e.g., the exterior face of the drywall). Pinching action created by the spring clips 140 holds the mounting ring 110 in place.
In a new-construction application, the mounting ring 110 may installed after a pre-construction brackets 1200, cabling and wall and ceiling surfaces (e.g., drywall) have been installed, but sill prior to completion of construction at the jobsite. Referring to
The mounting ring 110 is installed in the pre-construction bracket 1200 similar to installation directly into the wall or ceiling surface (e.g. drywall). The mounting ring is inserted into the hole defined by the pre-construction bracket 1200 and during insertion, the spring clips 140 are pressed back against the mounting ring body 130, but then spring back once within the hole. The mounting ring 100 is pressed snugly into the hole, such that the spring clips 140 slide through their range of motion, so that the back-bent portions 145 engage the interior face pre-construction bracket. In a typical installation, the mounting ring flange 135 engages the exterior face of the wall or ceiling surface (e.g., the exterior face of the drywall). In a flush-mount installation, the mounting ring flange 135 may engage the mud housing. Pinching action created by the spring clips 140 holds the mounting ring 110 in place.
The device can 120 includes a substantially cylindrical device can body 150 sized with a diameter slightly smaller than the mounting ring body 130, and a device can flange 155 that extends radially from the device can body 150, at its bottom end. The device can body 150 and device can flange 155 may be integrally formed, or may be separate components that are joined together. A number of (e.g., 4) magnets 160 are disposed in the device can flange 155. The magnets 160 may be disposed in holes that extend through the device can flange 155 from its top surface to its bottom surface. Alternatively, the magnets 160 may be disposed in depressions or upon the surface. The magnets 160 may be retained in place by a pressure fit, adhesive or other form of ridged attachment. The device can flange 155 may have a raised lip 157, having a diameter slightly larger than the mounting ring flange 135. The raised lip 157 may be raised on both the upper side and the lower side of the device can flange 155.
Referring to
A number of (e.g., 4) additional spring clips 165 may be affixed to the device can body 150 and extend outward therefrom. The additional spring clips 165 may be affixed to the device can body 150 using fasteners (e.g., rivets, screws, etc.) or other ridged form of connection, and may be made from a material that returns to its original shape after significant deflection (e.g., spring steel).
Device internals are disposed in the device can 120. In an embodiment where the device is a speaker, such as the active speaker shown in
In a typical installation, an installer installs the device can 120 at a second time, often at a late stage of the project. In a retro-fit application, the second time may be when all cabling has been installed and the project is drawing towards completion. In a new construction application, the second time may be when construction is substantially complete, and delicate device internals are less likely to be damaged from dust, debris, impact, moisture, etc. To install the device can 120, the installer connects cabling to the device can, and then inserts the device can body 150 into the hollow cavity defined mounting ring body 130 and presses it therein. The device can 130 is retained by a combination of the magnets 160, which are attracted to the mounting ring flange 135, and spring force of the additional spring clips 165 engaging with the inner surface and top rim of the mounting ring body 130 which provides additional mounting security. In some cases, for example, where the device is an active or passive speaker, the installer may complete the installation by applying the grille or faceplate 170 to the bottom face of the device can 120, which is held in place by the magnets 160. In such a case, magnets 160 may play a duel role, serving to both help retaining the device can 120 in the mounting ring 110, and to retain the grille or faceplate 170.
Should it be required, the installer can remove the device can 120 from the mounting ring 120 by grasping and pulling upon the device can flange 155. The additional spring clips 165 may allow for smoother removal and minimize the potential of dropping the device can 120. Magnets may transition from a high force of attraction to a low force of attraction rapidly with increasing distance. Such transition may prove startling to the installer, increasing a risk of dropping the device can 120. The additional spring clips 165 may provide resistance over a longer distance, as they engage and drag against the inner walls of the mounting ring body 130, smoothing out the force required for removal.
The device mounting system 100 may provide a number of advantages over prior designs. For example, the installation of the device can 120 into the mounting ring 110, and the mounting ring 110 into the hole in the wall or ceiling surface (e.g., drywall) may be tool-less, being performed simply by a press fit. Issues of over tightening or under-tightening screws, and potential damage to a flange or the wall or ceiling surface (e.g., drywall), or lack of secure mounting, are avoided. Further, the device can 120 may be easily removable from the mounting ring 110. If repeated removals are required, they can be conducted without wear upon, and potential damage to, the wall or ceiling surface (e.g., the drywall). Still further, the device mounting system 100 may be flexibly used, permitting work to be performed at the times most convenient in new construction and retro-fit workflows, and when damage to device internals may be best avoided.
It should be understood that a device mounting system 100 may be constructed in a variety of different sizes to support different sizes and types of devices. For example, the device mounting system may be used constructed in 4 inch (in), 5 in and 6.5 in configurations, among others.
Further, it should be understood that many different adaptations and modifications may be made to the device mounting system 100. For example, while an example embodiment is discussed above in which the mounting ring 110 and device can 120 each may have a substantially cylindrical body 130, 150, it should be understood that the mounting ring 110 and device can 120 may have different cross sections (e.g., a rectangular cross section, a rounded rectangle cross section, a square cross section, an oval cross section, etc.), such that the mounting ring body 130 and the device can body 150 may substantially resemble a variety of different types of prisms. Accordingly, the terms “ring” and “can” should be interpreted broadly to encompass different cross sections, and forming types of prisms other than cylinders.
Further, while an example embodiment is discussed above in which the mounting ring flange 135 is made of a ferromagnetic metal (e.g., steel) and the grille or faceplate 170 includes ferromagnetic metal (e.g., steel) pieces, so that magnets 160 in the device can flange 155 are attracted to both of them, it should be understood that different arrangements are possible that utilize the principle of magnetic attraction in different ways. For example, magnets may be mounted in the mounting ring flange 135 and/or grille or faceplate 170 to interact with magnets 160 in the device can flange 155. Alternatively, magnets may be mounted in the mounting ring flange 135 and/or grille or faceplate 170, and no magnets mounted in the device can flange 155. In such a case, the device can flange 155 may be constructed of a ferromagnetic metal (e.g., steel) to permit attraction. A wide variety of additional configurations using one or more magnets are expressly contemplated.
Additionally, while an example embodiment is discussed above in which the device can 120 is retained in the mounting ring 110 by a combination of both magnetic attraction of magnets 160 and spring force of additional spring clips 165, it should be understood that only a single one of these modes may be used. For example, the device can 120 may be retained only with magnetic attraction of magnets 160, or the device can 120 may be retained only with spring force of additional spring clips 165.
Above all, it should be understood that the above embodiments are meant to be taken only by way of example.
The present application claims the benefit of U.S. Patent Application No. 62/620,264 filed on Jan. 22, 2018 by Cary L. Christie, entitled “Tool-Less Speaker Mounting System”, the contents of which are incorporated by reference herein in their entirety.
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