Flush Mount Panels With Interconnects

Abstract

The present invention provides a system and method of aligning wall or ceiling mounted components. The mounted components are placed within brackets which, in turn, are placed within panels that are embedded into the wall or ceiling. The panels are pre-designed to be installed in precise alignment with respect to one another using various alignment tools or interlocking methods. Once the panels and components are installed into the wall or ceiling, the components are automatically aligned with respect to one another.

Description

This application is a continuation-in-part of Ser. No. 11/954,667 filed Dec. 12, 2007, which is a continuation-in-part of Ser. No. 11/566,365 filed Dec. 4, 2006, which claims priority to provisional application Ser. No. 60/825,162 filed Sep. 11, 2006 and also claims priority to provisional application Ser. No. 60/950,237 filed Jul. 17, 2007 and International application ser. no. PCT/US07/16404 filed Jul. 19, 2007. All prior applications are incorporated by reference in their entirety.

FIELD OF THE INVENTION

The field of the invention is wall and ceiling receptacles.

BACKGROUND

Plasma screens, speakers, light switches, electrical outlets, recessed lighting, junction boxes and other components are conventionally mounted by cutting a hole in a wall or ceiling, inserting a bracket, and then installing the component into the bracket. When several components are mounted on the same wall or ceiling, installers typically attempt to line up the components or space out the components in an aesthetic pattern. Under those circumstances, being able to mount multiple components in a wall or a ceiling in precise locations relative to one another can become very important to achieve a clean and exacting appearance. However, since the cutouts are performed at the job site, it can be difficult to line up or evenly space multiple components. Even where the task can be performed, there is a considerable amount of work exerted in taking measurements and making minor adjustments.

One method of lining up mounted components is to attach them along a length of a beam, joist or other substantially straight support structure. U.S. Pat. No. 5,056,287 to Weber teaches a ceiling light system attached directly a ceiling joist along a straight line. U.S. Pat. No. 5,609,007 to Eichner teaches attaching components to a grid in a ceiling. Weber, however, is ineffective at attaching components in positions other than along a ceiling joist, and Eichner cannot be used for recessed components integrated with the existing wall or ceiling. These and all other extrinsic materials identified herein are incorporated by reference in their entirety. Where a definition or use of a term in an incorporated reference is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein applies and the definition of that term in the reference does not apply.

Lining up components of different sizes along a beam or a grid can also prevent an installer from aligning the components along different axes. In FIG. 1, for example, three components of differing sizes 20, 30, and 40 are attached to a side of ceiling joist 10. Attaching the components directly to the support beam means that the centerlines of the components are out of alignment with one another. U.S. Pat. NO. 6,431,723 to Schubert teaches a method of aligning the centerline of components by adding additional support beams between existing ceiling joists. However, adding additional support beams for each mounted component is time consuming, labor intensive, and is still prone to errors if the installer makes a measurement mistake.

Another method of mounting components is to prefabricate an entire wall with framed cutouts located where the components are to be installed. US 2007/209,305 to Douglas teaches building pre-fabricated housing with pre-cut windows and pass-throughs. However, building an entire wall in advance at an off-site location is very often impractical, especially when making a late installation decision after a wall has been installed. Additionally, none of the prior art teaches arranging mounted components that achieve a flush-mount appearance in walls, ceilings, and other structures, in which little or even no finishing is required around the periphery of the opening.

Thus, there is still a need for methods of mounting multiple components in a substantially flat structure of a building at precise locations relative to one another.

SUMMARY OF THE INVENTION

The present invention provides apparatus and methods in which a plurality of components are mounted into a wall, ceiling, or other wallboard by aligning panels with brackets that hold the components. Typically, a wallboard is a building board made for surfacing rather than for insulating ceilings and walls. Wallboards are often made into large rigid sheets that are fastened to the frame of a building to provide a surface finish. As used herein, the term “wallboard” should be construed broadly to mean any sort of mechanical barrier for surfacing ceilings or walls. Wallboards can be made of any suitable material, including for example plywood, plaster, wood, wood pulp, or gypsum.

Preferred panels have compositions and thicknesses that match the wallboard to which they are being finished, in terms of thickness, composition, and so forth. Where there are differences in composition or thickness, it is preferred that the moisture absorption rate and the thermal expansion rate of the panel and the wallboard differ by no more than 30%, 20%, 10% or 5% from one another to prevent cracking and fraying. Contemplated panel materials include polymers, plasters, woods, fiberboards, and gypsum. The panels can be pre-fabricated away from a construction site, preferably in a factory that can cost-effectively fabricate devices with relatively small tolerances.

Each panel preferably has at least one receiver that can be factory fabricated into one contiguous assembly. Such receivers can advantageously be made of a strong and durable thermoset bracket, or other material that is more suited to hold a mounted device than the gypsum typically used in wallboards. Providing a pre-fabricated panel designed to accept specific components greatly facilitates installation by eliminating the need for on-site precision measurements.

Additional receivers can be affixed to openings in the panel, which openings typically extend from a front side of the panel to the back side of the panel. Receivers can range from a simple rim disposed on the inside of the opening to an extensive bracket and housing extending out the back of the panel. In any event, completed assemblies preferably have little or no discernable gap between the panel and the receiver. This can be accomplished in any suitable manner, including for example, accurately cutting the opening into which the receiver is installed and then gluing the receiver to the panel. Where the panel comprises a formed substance such as drywall, another option is to form the panel around the receiver.

Since the panels are preferably anchored to a support structure using a screw, nail, or similar attachment mechanism, the panels are first aligned with respect to one another before anchoring. Panels can be aligned in any suitable way, for example lining up the edges of the panels, lining up the centerlines of the panels, lining up the centerlines of the receivers, making two edges parallel to one another, or making two edges perpendicular to one another. It is appreciated that aligning the panels in a proper or desirable coordination relative to one another also aligns the receivers relative to one another, and in turn aligns the components relative to one another once everything is installed.

One or more of the panels preferably have an alignment mechanism to help align panels with one another. In a simple embodiment, the edges of the panels interlock and mate with one another. Such interlocks can advantageously be operated without the use of any tools, for example with snaps, butt joints, dovetails, matching tongues and grooves, matching indents and detents, or matching mortises and tendons. A joint compound, glue, or other such material may be used to permanently or semi-permanently affix the panels to one another, but is not necessary.

In other embodiments, the edges may be aligned by abutting matching alignment indicators on both panels, and then attaching the panels together using fasteners that couple to fastener receivers on both panels. For example screws could thread into pocket holes, U-bars could be inserted into matching recesses, hooks could be coupled to loops or eyes, nails could be hammered through marked indicators, and pegs can be inserted into matching holes.

Where the panels do not abut one another, alignment mechanisms more appropriate for distance alignment could be used. For example, an installer could aim a laser light connected to a first panel towards a second panel, and then could adjust the second panel so that the laser light intersects one or more alignment designators on the second panel. Alignment designators could be a line drawn on the panel, or could be two dots that form a line when connected, or could even be an edge of the panel or receiver.

In preferred embodiments, each receiver has a spackle shield that covers the opening. Receivers can advantageously include useful installation tools, for example a level, installation screws, an alignment mechanism, or installation instructions. In the figures, each of the receivers also has an optional spackle rim or lip that extends outwardly from the front surface of the panel by a small distance. Preferred distances are less than ½ inch (1.27 cm), more preferably by only ⅛ inch (3.175 mm), and even more preferably 1/16 inch (1.5875 mm). Spackling compounds, for example plaster or drywall, can then be smoothed over the surface of the wallboard and panel up to the spackle rims to achieve a contiguous visual appearance.

Panels are typically installed into the wallboard by first approximating the edges of the panel with the edges of the wallboard to form a junction between the edges. If the junction or gap between the edges is rather large, a buffer can be attached to the edge of the panel before installation, or one or more shims can be installed into the junction. The junction can then be concealed with a concealant, or combination of concealants, to cover the junction from view and establish a superficially continuous junction between the panel and the wallboard. A junction is superficially continuous when the wallboard and the panel appear to be one piece when inspecting the wallboard using visual and/or tactile means. Preferred concealants include tape, plaster, spackling compound, glue, varnish, and paint.

All types of components are contemplated for installation, but especially including components having electrical parts. For example, speakers, lights, switches, wall plugs, wall controls (audio, video, fan), thermostats, fire sprinklers, fire alarms and smoke alarms, mirrors, kitchen appliances, intercoms, air vents, vacuum outlets, security panels, and iPod docks and ports are all contemplated components.

The components are preferably locked into place within the receivers using movement restrictors, for example detents, latches, biasing mechanisms, locks, or magnets. Preferably, the movement restrictors engage as the component is inserted into the receiver. “Locking” a component within a receiver means that the component is substantially restricted from moving in a direction relative to the receiver, for example by 2 mm (0.0787 in), 1 mm (0.0394 in), or 0.5 mm (0.197 in). Special removal tools are contemplated for releasing and withdrawing the component. For example a latch can be attached to a ferrous metal or magnet so that a magnetic tool unlocks the latch from the component, allowing it to be removed from the receiver.

Various objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description of preferred embodiments of the invention, along with the accompanying drawings in which like numerals represent like components.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 is a plan view of prior art components mounted to a ceiling joist.

FIG. 2 is a front plan view of a first panel with a laser light and a second panel that is aligned using the laser light.

FIG. 3 is a front plan view of two panels with interlocking dovetails.

FIG. 4A is a front plan view of two panels with an interlocking tongue and groove.

FIG. 4B is a horizontal cross-section of along line 4B-4B of the panels of FIG. 4A

FIG. 5A is a rear plan view of a first panel with a recess and a second panel with a recess and a pair of U-bars.

FIG. 5B is a horizontal cross-section along line 5B-5B of the panels of FIG. 5A.

FIG. 6A is a rear plan view of a first panel with an angled screw hole and a second panel with a pocket hole.

FIG. 6B is a horizontal cross-section along line 6B-6B of the panels of FIG. 6A and a screw that fits in the pocket hole and the screw hole.

FIG. 7A is a front plan view of a first panel with a pair of recesses, a second panel with a recess and a protruding tab, and a peg.

FIG. 7B is a horizontal cross-section along line 7B-7B of the panels of FIG. 7A.

FIG. 8 is a front perspective view of one of the brackets in FIG. 2.

FIG. 9 is a simplified vertical cross-section of the panel and bracket of FIG. 2, taken along line 9-9, installed in a wall and with an attached speaker.

FIG. 10 is a blown up view of the circled portion of FIG. 9.

FIG. 11A is a front perspective view of the bracket of FIG. 8 positioned to couple with a bracket backing.

FIG. 11B is a simplified vertical cross-section of the panel of FIG. 2, taken along line 9-9, with the bracket and bracket backing of FIG. 11A.

FIG. 12A is a front perspective view of a panel being affixed to two studs in a wall, the panel having a spackle shield covering an opening.

FIG. 12B is a front perspective view of the panel of FIG. 12A, around which drywall has been installed.

FIG. 12C is a front perspective view of the panel and drywall of FIG. 12B, showing mesh tape.

FIG. 12D is a front perspective view of the panel and drywall of FIG. 12C, where the mesh tape has been covered by spackle.

FIG. 12E is a front perspective view of the panel and drywall of FIG. 12C, where the spackle shield has been removed to show the opening.

FIG. 13A is a perspective view of two structures in a building (e.g. walls or wall and ceiling), in which an opening has been cut to receive a panel assembly.

FIG. 13B is a perspective view of the two structures of FIG. 13A, in which the panel assembly has been placed within the opening.

FIG. 13C is a perspective view of the two structures of FIG. 13B, in which the approximated edges of the panel assembly and the wall have been finished to provide a superficially continuous junction.

FIG. 14 is a rear view of the panel assembly of FIGS. 13A-13C, showing a receiver and attachments.

FIG. 15A is a horizontal cross-section of a panel assembly and speaker component installed in a wall, where the component is seated to the assembly using magnets.

FIG. 15B is a horizontal cross-section of a panel assembly and switch component installed in a wall, where the component is seated to the assembly using a long bolt.

FIG. 15C is a horizontal cross-section of a panel assembly and light component installed in a wall, where the component is seated to the assembly using a detent.

FIG. 15D is a horizontal cross-section of a panel assembly and a generic component installed in a wall, where the component is seated to the assembly using friction surfaces.

FIG. 16 is a perspective view of a panel assembly being formed by pouring a panel material into a mold.

DETAILED DESCRIPTION

In FIG. 2 a component mounting apparatus 200 generally includes a panel 210, with opening 220 and panel 260 with opening 270. It should be appreciated that while each bracket is sized and dimensioned to hold a specific component, the brackets could be identical to one another to create a “universal bracketing system” that can hold components of various sizes.

Panel 210 and panel 260 are preferably substantially identical to one another in terms of shape, size, dimensions, and material, but can vary from one another without departing from the scope of the previous invention. Where the specification refers to only one panel in a figure, it is to be assumed that the other panel in the figure has the same features, unless otherwise stated.

Panel 210 is a piece of gypsum board, wood, plastic, or other material (or combination of materials) sufficiently strong to support a speaker or other desired component between two studs of a wall, or joists in a ceiling, or other supports. Where plywood is used as the panel material, for example, the panel might be as thin as ¼″ (6.35 mm), but would more preferably measure at least ½″ (12.7 mm) or ⅜″ (19.05 mm). Preferred materials include wallboard, Medium Density Fiberboard (MDF), High Density Fiberboard (MDF), Acrylonitrile Butadiene Styrene (ABS), and other materials that closely match various characteristics of drywall. Multiple materials could be used, for example mixed in with one another, alternating, layered on top of one another, or a combination. Preferably, the material has equal moisture absorption and coefficient of thermal expansion as the surrounding wallboard, while having greater durability and strength for attaching heavy components directly to the panel. For example QuietRock® 525 could be a paneling material used where the wallboard comprises drywall.

Panel 210 is typically about twenty inches (about 50 cm) to twenty-four inches (about 60 cm) wide, but other contemplated panels can have any other suitable dimensions, even for example, up to the size to replace an entire sheet of wallboard. Narrower panels are also contemplated, although they would likely not have a sufficient width to extend between wall studs or ceiling joists. Suitable panels would usually have a width of at least six inches (15.24 cm) or twelve inches (30.48 cm) greater than the spacing between studs, which allows the installer considerably greater flexibility in positioning the panel on the wall. Lateral wings (not shown) could be attached to the perimeter of panel 210 to extend the width for installations where the studs are spread apart at a greater distance from each other than normal. While panel 210 is shown as a substantially planar apparatus, panel 210 can be concave, convex, or any other shape to either match the shape of the wallboard, or to introduce a non-planar surface to the wallboard.

Panels 210 and 260 are could be aligned along their top or bottom edges, aligned along a centerline, or could be arranged in a staircase fashion with a top edge aligned to a bottom edge. In FIG. 2, laser light 240 and an alignment indicator 290 are used to align panel 220 with panel 210 along a centerline marked by laser beam 242. Alignment indicator 290 is shown as a line marked along a horizontal centerline of 270, but could be any other suitable alignment indicator, including a series of marks in a row, an edge of panel 260, or an edge of opening 270. While the alignment indicator is generally a straight line, the indicator can be a curve or other shape, especially if the opening or bracket is not straight. Laser light 240 could also fan out a second line (not shown) that runs perpendicular to laser beam 242 to designate a second axis of alignment. One of ordinary skill in the art would appreciate that a second line could necessitate a second alignment indicator on panel 260. Additionally, since lasers can fan out lines in multiple directions, a laser level could be used to align panels placed on different wallboards of a room.

Hole primers 212, 262 are spaced approximately 1 inch (2.5 cm) from center, a diameter of 0.375 in (9.525 mm), and are approximately ¼ in (6.35 mm) deep, but can be shaped and configured in other suitable ways. A “hole primer” is a concave hole deepest in the center that helps an installer drill a screw or hammer a nail in a designated place without slipping. The diameter of the hole primer is preferably larger than the diameter of the screw head or nail head used so as to prevent the head of the screw or nail from leaving an unsightly bump on the surface of the wallboard after spackling. Other suitable receivers are contemplated, for example visual marks or pre-drilled and threaded screw holes.

Each opening 220, 270 can also be of any suitable shape and size. Preferred openings are rectangular to accommodate common rectangular components, for example light switches, wall outlets, speaker volume controls, and home security systems. However, the openings could also be oval or circular or any other desired shape. The area of the opening is generally dependent on the size of the component, and can range up to 80 in² (about 520 cm²) or larger. Especially preferred openings have an area of at least 20 in² (about 130 cm²), 40 in² (about 260 cm²), 60 in² (about 390 cm²), and even 80 in² (about 520 cm²). Nevertheless, for stability, it is contemplated that the panel would have openings with a length that is no more than half or one third the length of the panel.

The openings 220 and 270 are shown to be identical in height, and are centered in each panel, but it should be appreciated that the openings need not have any shared dimensions, and could be positioned in any suitable arrangement relative to the panels 210 and 260, respectively. Openings could be cut at a job site or elsewhere by an installer, but are more conveniently precut (or molded to include the opening) at the manufacturer. It is possible for a panel to have punch out openings or perhaps cutout lines to facilitate selection of the position of the opening at the job site, but those options are currently disfavored relative to a manufactured pre-cut or molded opening and a relatively large panel.

Brackets 230, and 280 are preferably sized and dimensioned to fit snugly into the openings 220 and 270, respectively, but in any event are screwed, glued, clamped, or are otherwise securely attached to the panels 210 and 260, respectively. The secure attachment is important since in at least some embodiments, the component housing will be attached to the bracket rather than being directly attached to the panel. The brackets are preferably molded from polyethylene or other sufficiently strong and durable thermoset plastic, and as shown in greater detail in FIG. 8 bracket 280 includes holes 282 for screws (not shown), a recess 284 into which a component cover 914 can be removably secured via a holding mechanism, and a rim 280A, and optional magnets 286 or an optional press fit (not shown).

Spackle shields 224 and 274 preferably cover openings 220 and 270, respectively, to prevent mud or drywall from entering the interior of the brackets, and can be removed after spackling. This is particularly helpful for when an electronic component is pre-installed behind the panel before spackling. Spackle shield 175 can have optional level 177 to help ensure that the panel is being installed horizontally. While level 177 is shown as a standard spirit level, any device that ensures that the panel is level is appropriate. Other devices that assist in installation can be provided in the spackle shield, for example a laser leveler to help align several panels with one another or a compartment that stores extra screws and magnets.

The components mounted to brackets 150, 160, and 170 can be any components mounted to a wall, for example speakers, plasma screens, in wall art panels, in wall cabinets, windows, wall outlets, security systems, fuse boxes, light switches, lighting, sprinkler systems, smoke detectors, and so forth. While the brackets and openings are generally shaped and sized to fit particular electronic devices, for example a rectangle for a light switch or a circle for a ceiling light, the universal brackets may be used that can accommodate a variety of electronic devices. To fit the component to a universal bracket, the component could consist of an outer casing that fits around the electronic device and couples to the universal bracket.

FIG. 3 shows an alternative component mounting apparatus 300 with panel 310 and panel 360. Similar to mounting apparatus 200, panel 310 has opening 320, bracket 322, and spackle shield 324, and panel 360 has opening 370, bracket 372, and spackle shield 374. In the present embodiment, spackle shield 374 also has a level 375 that assists an installer level panel 360. More importantly, panel 310 has protrusion 330 and recess 340 that interlock with recess 390 and protrusion 380 on panel 360, much like dovetail joints. The interlocking edges of panel 310 and 360 not only help mate the two to one another, but also act as an alignment mechanism to help align the position of panel 310 with respect to panel 360. Protrusion 330 and recess 390 are shaped differently than the other protrusions to ensure that the panels interlock in only one way. While adding one or more such “unique protrusions” is advantageous, ensuring that the panels interlock in only one way is not necessary. Indeed, in some situations it may be beneficial to the installer to use panels that can interlock in multiple ways, so as enable a small variety of alignment positions.

When the edges are interlocked, the top and bottom edges of panel 360 are in line with the top and bottom edges of panel 310. It is appreciated that different configurations of interlocking edges can bring the panels into other desirable coordinations relative to one another without departing from the scope of the present invention. Edges that “interlock” with one another can be sized and shaped to interlock directly with one another, or can have recesses that mutually receive a single peg, pin, screw, U-bar, or other similar device, as shown in FIGS. 5-7.

The panels are aligned when the interlocking edges of the panels are approximated to one another. “Approximating” is defined herein to mean bringing the edges near or towards one another so that the junction or gap between the edges is less than 10 mm (0.394 in), 5 mm (0.197 in), or even 2 mm (0.079 in). Preferably, the panels are glued to one another before mounting onto the wallboard. The junction can also be taped and/or covered with a spackling compound to both join the panels and prevent the panels from skewing or misaligning.

Interlocking protrusions and recesses do not have to be formed on the major planes of the panels. For example, in FIGS. 4A and 4B, a component mounting apparatus 400 has panel 410 with a recess 420 and a panel 460 with a matching protrusion 470. As shown more clearly in FIG. 4A, the protrusions and recesses are cut are tongues and grooves instead of dovetails. All other suitable ways of forming interlocking edges are contemplated, including for example using matching snaps, butt joints, and mortise/tendons.

FIGS. 5A and 5B shows another alternative component mounting apparatus 500 that aligns panels 510 and 560 using recesses 520 and 570, respectively, located on the backside of the panels. As U-bar 550 mates with recesses 520 and 570, the panels are more accurately aligned. U-bar 550 is a bar with square-shaped pegs that interlock with recesses on both panels and holds the panels in alignment relative to one another. The pegs and recesses may be any suitable shape, but is preferably non-circular to prevent the pegs from twisting within the recess. Additionally, glue or matching indents/detents could be used to prevent U-bar 550 from slipping out of recesses 520 and 570. While it is appreciated that recesses 510 and 560 could also be located on a front of the panels, it is preferred that the recess is on the back of the panel to prevent bulging on the front of the panel. Multiple sets of U-bars and recesses can be used to ensure that the panels do not fall out of alignment.

FIGS. 6A and 6B shows an alternative component mounting apparatus 600 that aligns panels using screws and screw-holes. An installer can abut the edges of panel 610 and panel 660 with one another while threading screw 650 through pocket hole 670 in panel 660 into screw-hole 580 in panel 610. Pocket hole 670 is preferably sized and dimensioned such that when screw 650 is fully screwed in pocket hole 670, the head of screw 650 does not protrude from the back surface of panel 660. Multiple screws and pocket holes are preferred to help hold panel 610 in place against panel 660 and ensure that the panels do not fall out of alignment.

FIGS. 7A and 7B illustrates yet another alternative component mounting apparatus 600 with panel 610 and panel 660, where the panels are aligned with respect to one another using pegs. An installer generally coats a wooden peg 650 with glue and inserts peg 650 into opposing recesses 620 and 670 in panels 610 and 660, respectively. The location of the recesses determines how the panels are oriented with respect to one another.

In FIG. 8, bracket 280 includes holes 282 for screws (not shown), a recess 284 into which a component cover 914 can be removably secured via a holding mechanism, and a rim 280A, and optional magnets 286 or an optional press fit (not shown). The brackets are preferably molded from polyethylene or other sufficiently strong and durable thermoset plastic, but any material suitable for supporting the weight of a component can be used.

FIG. 9 also shows a component 910 and a component cover 914. Component 910 is shown having speaker 912, but component 910 could be any practical component, including especially speakers, lights, air conditioners, or any other component that is typically larger than its external opening. The various wires for power and signal are not show in the Figures, but could be assumed, and can be those conventionally contemplated in the art. Component cover 914 can be any suitable grille, but is preferably a metallic mesh grille that press-fits into the opening 270. Additionally or alternatively, the component cover can include a ferrous material that is attracted to magnets 286 in bracket 280.

As seen in FIG. 10 the rim 280A is sized and dimensioned to extend outwardly beyond a front of the panel 260 by a very small distance 281, which provides a lip that can readily be used as a stop against which to spread a spackling compound, for example plaster or drywall. Preferred such distances 281 are less than ⅛ inch, and preferably about 1/16 inch, or in metric terms about 1-3 mm. Preferably, the panel has a thickness of at least ¼ inch (6.35 mm). Also shown in FIG. 10 is an attachment member 288 that helps secure bracket 280 to panel 260. A screw hole (not shown) can be provided in attachment member 288 to help affix bracket 280 to panel 260.

It should be appreciated that the rim could be separable from the panel. Thus, for example, the rim could be a separately molded piece of plastic, metal or composite that is installed into the opening by the installer, or at a factory.

As seen in FIGS. 11A and 11B, a bracket backing 1110 with screw holes 1112 could be used to clamp bracket 280 to panel 260. In this embodiment, attachment member 288 fits within recess 114 on the front of panel 260 and bracket backing 1110 fits within recess 266 on the back of panel 260. Screw 1114 threads through screw holes 282 and 1112, and finally through nut 1116 to provide a clamping force around panel 260. Clamping bracket 280 to panel 260 provides a secure connection without the need for expensive glues or adhesives.

In FIG. 12A, the panel 260 is affixed to two studs 1210A, 1210B in a wall, and screws 1215 are inserted through hole primers 262 and the panel 260 on the right side, and through an attached flange 264. Panel 260 shows opening 270 with a spackle shield covering the bracket. Of course, the positioning and orientation of the panel could be varied in any suitable manner with respect to the studs, 1210A, 1210B, including moving the panel 260 higher or lower, left or right, or even tilting the panel clockwise or counterclockwise. Similarly, the studs should also be interpreted herein as emblematic of any support structures of a wall, whether or not such structures are technically considered to be studs. In addition, a greater or lesser number of screws could be used, or inserted in some other arrangement than that shown to provide greater or lesser support. The screws could also be replaced or supplemented by some other attachment means such as an adhesive.

Those skilled in the art will appreciate that the combination of panel and bracket could be provided in several different ways. The panel and bracket could, for example, be joined together at a job site, and indeed the panel could even be “manufactured” at the job site by cutting or punching out the opening. More preferably, however, the panel and bracket are provided as an item of manufacture to the installer by a supplier or manufacturer. The rim of the panel can be pre-installed to the panel. Thus, in various embodiments a kit could contain one or more of a panel, a bracket (or at least a rim around the edges of an opening in the panel), a speaker housing, a spackle shield, and installation screws. The installer would then provide whatever labor is appropriate for the installation, including optionally installing the bracket and/or rim, optionally installing the spackle shield, and optionally mounting the speaker into the speaker housing to the back side of the panel. It is also contemplated that the speaker can be pre-installed into the panel before installation. Alternatively the combination of the panel and bracket can be mounted before installing a rim on the opening.

In FIG. 12B drywall 1220 or other wallboard has been installed on all four sides around the panel 260, and coupled to the wings using screws 1215. Where wings are present, as in the embodiment depicted, the drywall 1220 overlays the wings, but the wings are sufficiently thin so that the drywall is not noticeable raised. Those skilled in the art will appreciate that although FIG. 12B shows the drywall 1220 surrounding the panel 260 as a single piece, it is entirely possible that the drywall could comprise multiple pieces (not shown). It is also contemplated that installation of the drywall 1220 might be delegated to a drywaller or other tradesman distinct from the panel installer. Nevertheless, the process of installing the panel on one or more wall supports is deemed to include the step of positioning the panel so that it can be approximated in an end-to-end fashion by a piece of wallboard or other wall section.

In FIG. 12C mesh tape 1230 is applied along the juxtapositions or other approximations between edges of the panel 260 and edges of the drywall 1220. Here again, this step is usually delegated to a professional drywaller, but could be accomplished by the installer of the panel, regardless of which person actually does the work.

In FIG. 12D the mesh tape is covered by a spackling compound, and is ready for painting, wallpapering, or other surface coating. Preferably, the spackling compound is smoothed over the entire front surface of the panel to the lips of opening 270. As used herein, the terms “spackle” and “spackling” should be interpreted as broadly as possible, to include for example plaster and plastering of any type. One objective is to provide a smoothed out surface that completely or substantially hides the joints between edges of the panel and edges of the drywall

In FIG. 12E, the spackle shields are removed from openings 270 and components can be installed in the new uniform wallboard 1230.

In FIG. 13A an installation 1300 generally includes wallboards 1310, 1320, an opening 1314 on structure 1310, and a panel assembly 1330 comprising at least two interconnected panels 1332 and 1336 that will installed into the space 1314, as shown by arrow 1340.

As used herein, the term “assembly” means a group of objects that have multiple components or functional portions. Thus, the term comprises: (a) multiple pieces that are coupled together in some manner, either temporarily or permanently; and also (b) a single molded object with multiple functional components.

In typical installations, the wallboards 1310, 1320 would be adjacent vertical walls, or a vertical wall and a ceiling, and FIG. 13A should be interpreted to include all such embodiments. Thus, for example, where wallboards 1310, 1320 are interpreted to be vertical walls, members 1312, 1322 could be studs. Where wallboard 1310 is interpreted as a ceiling, members 1312 could be joists, and members 1322 could be horizontal struts. Although the portions of the wallboards 1310. 1320 depicted in the figure as substantially flat, those skilled in the art will appreciate that the structures could be curved, or have curved portions. In addition, those skilled in the art will appreciate that wallboard 1310 could exist independently of wallboard 1320.

Wallboards 1310, 1320 would typically comprise drywall, which term is used herein generically to include all manner of wallboard, fiberboard, gypsum board, GWB, plasterboard, Sheetrock® and Gyproc®, and so forth. Additionally or alternatively, wallboards 1310, 1320 could comprise other materials, including for example polymers, masonry, ceramics, and acoustic ceiling tile materials or other composites.

Wallboards 1310, 1320 can have any suitable dimensions, from only a few square feet or less, to hundreds of square feet or more. Wallboards 1310, 1320 will usually, however, have relatively small thicknesses of between ¼″ and 1″ in thickness.

Panel assembly 1330 can be produced at a job site, for example, by interlocking two pre-fabricated panels with brackets, preferably before the assembly is inserted into the wallboard space 1314. The panels could be glued together to prevent the panels from unlocking from one another. While the assembly is shown as one piece in FIG. 13A, it is to be appreciated that an assembly can be made of two panels that are not directly connected to one another, and are instead aligned at a distance using a laser light.

As discussed above with respect to FIGS. 2-12, the openings 1334, 1338 of FIG. 13A can be any suitable size, shape, or number. As currently contemplated, it is desirable that the total front facing area consumed by the openings be relatively small with respect to that of the panels 1332, 1336. That ratio is preferably at least 3, more preferably at least five. Viewed from another perspective, it is preferred that the panels 1332, 1336 extend in at least one direction at least 3 inches (7.62 cm) from the closest edge of the openings 1334, 1338, respectively for light or other simple switches, electrical outlets and so forth, and at least 5 inches (12.7 cm) for lights, more complicated switches and other controllers, speakers and so forth. Where the component has a front-facing surface area of at least 25 in² (about 160 cm²), the panels 1332, 1336 extend in at least one direction at least 12, 18, or even 24 inches (about 30, 45, or 60 cm) from the closest edge of either opening 1334 or 1338.

In FIG. 13B the panel assembly 1330 has been placed within the space 1314. There will almost always be some gap between the edges of the panel assembly 1330 and those of the surrounding structural component 1310, ranging in typical installations from zero (where the panel assembly 1330 is abutted against the structural component 1310), and perhaps 1/13″ (3.175 mm) to ¼″ (6.35 mm). Indeed, there will almost always be multiple different gaps around the edge of the panel assembly. Where the workmanship is sloppy, or the project is especially difficult, the gap in some sections can be larger. In addition, it is contemplated that an intermediate member (not shown), as for example a paper, shim, or even a frame can be installed in the gap between the panel assembly 1330 and the structural component 1310. As long as the edges of the assembly and the structure are somewhat near each other, and the gap can be finished and concealed such that an at least superficially continuous junction is established between them, the edges are considered to be approximated.

In FIG. 13C the approximated edges of the panel assembly and the structure have been finished to provide an at least superficially continuous junction. As used herein the term “at least superficially continuous junction” refers to a junction that appears to casual observation to be seamless. By way of example, a good workman-like job in taping and plastering adjacent sections of wall board is considered herein to produce an at least superficially continuous junction, especially where subsequent painting or wallpapering eliminates any seam apparent to casual observation.

In FIG. 14 a rear view of the panel assembly 1330 of FIGS. 13A-13C shows a receiver 1410 and attachments 1420 of the receiver to the panel 1332. The receiver 1410 in this instance is an open box, but all manner of alternative receivers are also contemplated. For example, receivers could be tubular or have some other shape, could be completely or partially closed, could be larger, smaller, or the same size as the opening, and can have punch outs such as those found on a typical electrical connection box. An exemplary receiver made to accept an electrically powered component could have electrical connections that mate with electrical connections on the component as the component is pushed into the receiver. Preferably, the electrical connections both power the component, and connect the component to other electrical devices.

The attachments 1420 are shown as four wings, extending from the four sides of the receiver 1410, and then glued, nailed, stapled or otherwise affixed to the panel 1332. Those skilled in the art will appreciate that still other methods could be used, including forming the panel 1332 around the wings or attaching the receiver to a bracket on panel 1332. Still further, it is contemplated that wings could be eliminated altogether. In a ¾″ or 1″ thick fiberboard, for example, a collar pressed into the opening, or used as a form around which the fiberboard is made, might have sufficient strength to hold a relatively lightweight component.

FIGS. 15A-15D depict alternative mechanisms for coupling and/or locking various components 1561-1564 within receivers 1410. In FIG. 15A the mechanism comprises magnets 1572 that lock to a magnetic portion of component 1561. The component can then be removed from the receiver by attaching a stronger magnet to component 1561, and pulling component 1561 away from magnets 1572. In FIG. 15B, the mechanism comprises a long threaded bolt 1574A that is turned into a nut 1574B. In FIG. 15C the mechanism comprises detents that fit within biasing members 1576B. In FIG. 15D the mechanism comprises a compressible polymer or fabric that fits in the gap between the rear portion 1564B of the component 1564, and the receiver 1410. In this particular example, the facing plate 1564A of the component 1564 is larger across than the rear portion 1564B.

In the Figures component 1561 is a speaker or other speaker assembly 1561 A, component 1562 is a light or other switch, (showing toggle 1562A), component 1563 is a light, light fixture or other light assembly, and component 1564 is a generic component that could euphemistically be viewed as an electrical outlet, or any other reasonably installable component. Of course, the combinations expressly depicted in the Figures are merely examples, and thus it should be appreciated that one could combine any of the components 1561-1564 with any of the depicted seating mechanisms, or indeed any suitable seating mechanism.

FIGS. 15A-15D also demonstrate that the face of the components are only optionally made completely flush with the face of the panel 1332 when they seat with the receiver 1410. FIG. 15D, for example, shows a face portion 1564A that is recessed from the face of the panel 1332. Here, those skilled in the art will appreciate that the recess is exaggerated to assist visualization. In practice, any such recess or extension would likely be less than ⅛^th inch (3.175 mm). Furthermore, it is contemplated that the components can be easily removed by extraction tools, such as a screwdriver and the like, to provide for simpler change of installation.

FIG. 16 is a perspective view of a panel assembly 1610 being formed by pouring a panel material from container 1640 into a mold 1620. This process brings the poured material right up against the frame portion that defines the opening 1630, regardless of any irregularity or other difficulties with the shape of the opening. All manner of panel materials are contemplated, including for example curable plastics, and masonry composites.

Thus, specific embodiments and applications of flangeless speaker devices and methods have been disclosed. It should be apparent to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims. Moreover, in interpreting both the specification and the claims, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced. Where the specification claims refers to at least one of something selected from the group consisting of A, B, C . . . and N, the text should be interpreted as requiring only one element from the group, not A plus N, or B plus N, etc.

Claims

1. A system of mounting a plurality of electrical components into a wallboard, comprising:

a first panel having a first receiver that receives a first component of the plurality of components;

a second panel having a second receiver that receives a second component of the plurality of components;

an alignment mechanism that helps align the first panel with the second panel; and

a concealant that covers a junction between the first panel and the wallboard and a junction between the second panel and the wallboard.

2. The system of claim 1, wherein the first receiver comprises a lip extending beyond a front of the panel.

3. The system of claim 1, wherein the first panel and the first receiver are factory fabricated into one contiguous piece.

4. The system of claim 1, wherein the first receiver has a removable spackle shield covering an opening.

5. The system of claim 4, wherein the spackle shield has the alignment mechanism.

6. The system of claim 1, further comprising a movement restrictor that restricts a travel of the first component in a direction relative to the first receiver.

7. The system of claim 6, wherein the movement restrictor engages as the first receiver receives the first component.

8. The system of claim 1, wherein the alignment mechanism comprises edges on the first panel that interlock with edges on the second panel.

9. The system of claim 8, wherein the interlocking edges are selected from the group consisting of snaps, butt joints, dovetails, a matching tongue and groove, a matching indent and detent, a matching mortise and tendon, and a matching screw and pocket hole.

10. The system of claim 1, wherein the alignment mechanism comprises a laser light on the first panel, and an alignment designator on the second panel.

11. The system of claim 10, wherein the alignment mechanism further comprises a second alignment designator on the second panel.

12. The system of claim 1, wherein the concealant is at least one of tape and plaster.

13. The system of claim 1, wherein the junction is shimmed.

14. A method of aligning a plurality of components mounted in a wallboard, comprising:

providing a first panel with a first receiver that receives a first component of the plurality of components;

providing a second panel with a second receiver that receives a second component of the plurality of components;

aligning the first panel with the second panel;

establishing a first superficially continuous junction between a first edge of the wallboard and an edge of the first panel; and

establishing a second superficially continuous junction between a second edge of the wallboard and an edge of the second panel.

15. The method of claim 14, further comprising pre-fabricating the first panel with the first receiver.

16. The method of claim 14, further comprising locking the first component to the first receiver.

17. The method of claim 14, further comprising providing a tool that unlocks the first component from the first receiver.

18. The method of claim 14, wherein aligning the first panel and the second panel comprises interlocking an edge of the first panel with an edge of the second panel.

19. The method of claim 14, wherein aligning the first panel and the second panel comprises affixing a fastener to a first fastener receiver in the first panel and a second fastener receiver in the second panel.

20. The method of claim 14, wherein aligning the first panel and the second panel comprises:

coupling a laser light to the second panel;

activating the laser light to shine a laser on the first panel; and

positioning the first panel according to the laser light.

21. The method of claim 14, wherein establishing a first superficially continuous junction comprises spreading a spackle compound over the junction.