SYSTEM AND METHOD FOR MOUNTING A FLAT PANEL DEVICE

Abstract

A system and method for mounting a flat panel device are provided. The system includes a frame having a receiving space configured to receive a flat panel device therein, and a tension plate attached to the frame that provides for leveling of the frame and retention of the frame in the wall. The method includes providing a frame having a receiving space configured to receive a flat panel device therein and a tension plate attached to the frame, inserting the frame into a hole in a wall on which the flat panel device is to be mounted, adjusting the tension plate to level the frame and retain the frame in the hole, and mounting the flat panel device in the receiving space.

Description

This application claims priority to U.S. Provisional Application No. 61/051,485, filed May 8, 2008, which is hereby incorporated by reference.

BACKGROUND

Field

A system and method for mounting a flat panel device are disclosed herein.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments will be described in detail with reference to the following drawings in which like reference numerals refer to like elements, and wherein:

FIG. 1 is a front exploded perspective view of a flat panel device mounting system according to an embodiment;

FIG. 2 is a rear exploded perspective view of the flat panel device mounting system of FIG. 1;

FIG. 3 is a front view of the flat panel device mounting system of FIG. 1;

FIG. 4 is a partial exploded side cross-sectional view of the flat panel device mounting system of FIG. 1, taken along line IV-IV of FIG. 3, mounted to existing studs of a wall;

FIG. 5 is a top view of the flat panel device mounting system of FIG. 1;

FIG. 6 is a top cross-sectional view of the flat panel device mounting system of FIG. 1, taken along line VI-VI of FIG. 3;

FIG. 7 is a side exploded view of an exemplary of retaining plate, tension plate, and adjustment device according to an embodiment;

FIG. 8 is a side view of an exemplary flat panel device mounting rail according to an embodiment;

FIG. 9 is a rear view of the flat panel device mounting rail of FIG. 8; and

FIG. 10 is a flow chart of a method for installing a flat panel device according to an embodiment.

DETAILED DESCRIPTION

Embodiments disclosed herein relate to the mounting of flat panel technologies or devices, including but not limited to current flat panel technologies, such as liquid crystal display (LCD) devices, plasma display panel (PDP) devices, and similar devices, as well as future flat panel devices, such as OLED (organic light emitting diode) thin panel display devices, in a pre-constructed recessed cavity retro fitted in a non load bearing interior wall. Embodiments may provide a substantially ridged recessed wall mounting structure to support all sizes and styles of flat panel technologies without the need for heavy wall reinforcement, custom carpentry, or millwork. The recessed nature of the mount provides a clean look with hidden cabling path(s), and resolves potential ADA challenges in high walking traffic areas. Additionally, future recessed applications, such as post electrical back box, post low voltage cable management, in wall shelving, and the like, can benefit from this mounting application.

Embodiments may be constructed of carbon fiber or all metal components, such as steel, aluminum, sheet metal, and similar materials, creating a box style cavity, with universal mounting infrastructure, cabling pathways, sealed fire retardant construction, a mechanically adjusted leveling and locking device, suited for in wall recessed mounting of current and future flat panel technologies, such as LCD devices, PDP devices, or OLED devices.

FIG. 1 is a front exploded perspective view of a flat panel device mounting system according to an embodiment. The flat panel device mounting system 1 shown in FIG. 1 includes a frame 10. The frame 10 is configured to receive a flat panel device 500 in a cavity or receiving space 10a. The frame 10 creates a back cavity or recessed box for the flat panel device 500 to be recessed into a wall.

The frame 10 may be rectangular or another suitable shape corresponding to a shape of the flat panel device to be mounted. Further, the frame 10 may be formed of carbon fiber or a metal, such as steel, aluminum, sheet material, or a similar material. Furthermore, the frame 10 may be a solid structure molded, welded, or press formed, for example.

A front of the frame 10 may include a flange 10b configured to cover and seal an area of a wall cut for installation of the system 1. The flange 10b may extend around the front of the frame 10, as shown in FIGS. 1-3. The flange 10b may be, for example, approximately 2 inches in width; however, other widths may be appropriate based on a particular size and/or application of the mounting system.

The front (i.e. flange 10b) of the frame 10 may be capable of being resurfaced with, for example, paint, wood, plastics, and/or other decorative trims to a customer's requirements. Polished or brushed finishes may require treatment of the frame to accomplish a unique look.

The flat panel device mounting system 1 may further include one or more retaining plate(s) 20. The retaining plate(s) 20 may be attached directly to an existing stud 110, such as an existing wood or metal stud, of a wall by an attachment device, such as, for example, holes 20b and bolts 20c. The retaining plate(s) 20 may be formed of metal or another suitable material. A shape and dimension of the retaining plate(s) 20 may allow for an exact gauge of depth to be positioned on the stud 110 to an edge of a drywall or plaster wall surface. The retaining plate(s) 20 may each include a notch and angle 20a provided, respectively, at a top or bottom edge of the respective retaining plate 20 that allows a tension plate 30 and a locking wedge 120, discussed herein below, to firmly “lock” the frame 10 in position in a wall, as discussed herein below.

That is, the flat panel device mounting system 1 may further include the tension plate 30, which may be configured to be “locked” to the retaining plate(s) 20, as shown in FIGS. 3-7. In this embodiment, the tension plate 30 is shown attached to a lower exterior wall of the frame 10; however, alternatively, the tension plate may be attached to an upper or side exterior wall of the frame 10. The tension plate 30 functions to level and support the frame 10, and thus, the flat panel device 500. The tension plate 30 is configured to fit in a recess 20d formed by the notch and angle 20a of the respective retainer plate, as shown in FIG. 7. As shown in FIG. 1, an adjustment device 45, in this embodiment comprising one or more adjustment bolt(s) 50, washer(s) 60, and corresponding locking nut(s) 70 may be provided, the one or more adjustment bolt(s) 50 mating with one or more threaded hole(s) 30a provided in the tension plate 30. The tension plate 30 allows the frame 10 to be leveled by adjustment of the adjustment bolt(s) 50. Further, compressive force provided by the tension plate 30 maintains the positioning of the frame 10 in the wall.

In the embodiment of FIGS. 1-9, the one or more adjustment bolt(s) 50 carry a load of the frame 10 and flat panel device 500 to the tension plate 30. The adjustment bolt(s) 50 may be inserted through the frame 10 via one or more non-threaded hole(s) 50a at predetermined locations based on a size of the frame 10. The adjustment bolt(s) 50 may each receive a corresponding washer 60 and be held in place by a locking nut 70. The washer 10 may be provided on the respective adjustment bolt 50 between a head 50b of the adjustment bolt 50 and the frame 10, as shown in FIG. 1. The washer 60 may be attached or welded to the adjustment bolt 50 to limit vertical movement of the respective adjustment bolt 50. The locking nut 70 may be, for example, attached or welded to the adjustment bolt 50 to retain the connection between the tension plate 30 and the adjustment bolt 50. In the embodiment of FIGS. 1-9, use of the locking nut(s) 70 allow movement of the adjustment bolt(s) 50 downward, the retainer plate(s) 20 pushing upward to lift the frame 10 and “lock” it into position. The adjustment bolt(s) 50 may each be, for example, an approximately ½ inch bolt, approximately 2.5 to 3 inches long.

One or more mounting rail(s) 150 may be provided to mount the flat panel device 500 within the receiving space 10a of the frame 10, as shown in FIGS. 4 and 8. The mounting rail(s) 150 each may be in the form of a rail including one or more mounting rail hook(s) 150a. The embodiment of FIG. 4 includes two mounting rail hooks 150a. The mounting rail(s) 150 may be configured to be attached to the flat panel display 500, as shown in FIG. 4, by, for example, one or more locking stud(s) 80. In this way, a hook to rail assembly may be provided which mounts the flat panel device 500 in the receiving space 10a formed by the frame 10, as discussed herein below.

One or more mounting rail slot(s) 160 may be provided on the mounting rail(s) 150, as shown in FIG. 9. The mounting rail slot(s) 160 may be in the form of a slot cut into a vertical center line of the respective mounting rail 150. This allows for center line adjustment using a dead center mark 200 to a center line of a horizontal position of the flat panel device 500. The dead center mark 200 enables multiple sized flat panel devices to be installed and centered with respect to an interior of the receiving space 10a formed by the frame 10.

The one or more locking stud(s) 80 may be provided, to attach or “lock” the one or more mounting rail(s) 150 to the flat panel device 500, as shown in FIG. 4. The one or more locking stud(s) 80 may each be a threaded bolt. Further, a bolt head 80a of each of the locking stud(s) 80 may have locking edges or make use of a locking washer (not shown) to maintain its position.

One or more hanging rail(s) 90 may be provided within the receiving space 10a of the frame 10. The hanging rail(s) 90 may be formed integral with, attached to, or welded as a part of a cable channel(s) 40 as discussed herein below. The hanging rail(s) 90 allow the mounting rail(s) 150 and the mounting rail hook(s) 150a to latch onto the frame 10 to adjustably mount the flat panel device 500 within the receiving space 10a. The mounting rail hook(s) 150a may be in the form of a hook having, for example, an approximately ½ to ¾ inch deep edge that allows a respective mounting rail 150 to hook onto a respective hanging rail 90. The mounting rail(s) and hook(s) may be angled to allow for a tight gravity created fit.

As set forth above, the flat panel display mounting system 1 may further include one or more cable channel(s) 40 provided formed integral with, attached to, or welded to the one or more hanging rail(s) 90. The cable channel(s) 40 may be formed by welding a top and bottom of the hanging rail(s) 90 to an interior of the receiving space 10a of the frame 10. The cable channel(s) 40 allow cabling to be easily run from one side of the frame 10 to the other without interference from the flat panel device 500 or crossing video (low voltage) or power (high voltage) lines.

One or more j-box(es) 100 may be provided. Each j-box 100 may be, for example, an approximately 2 inch deep×approximately 3 inch tall×approximately 2 inch wide box formed integral with, attached to, or welded to the frame 10. A left side j-box 100, as shown in FIG. 1, may be configured to hold a power receptacle. A cover 130, which may be in the form of a “snap cover”, may be provided to seal and hide an opening for cable management and fire rating. A right side j-box 100, for example, may allow low voltage cabling to pass into the frame 10 and cable channel(s) 40 connecting to the flat panel device 500.

The one or more cover(s) 130 may each include at least one hole 130a through which electronic cabling may be passed. The one or more cover(s) 130 may be formed of an L shaped plate. The L shaped plate may be formed of metal, for example. Two small tabs (not shown) may be provided at a front of the L shaped plate to fit under an edge of the respective cable channel 40, firmly holding the plate in place as a top of the L shaped plate snaps under a front edge of the j-box 100. Removal of the respective cover 130 may be facilitated by a small notch (not shown) provided in a top of the L shaped plate and pulled loose with, for example, a flat head screw driver.

The existing wall stud(s) is/are referred to in the drawings by reference numeral 110. The existing wall stud(s) 110 may be, for example, standard studs, metal or wood, commonly called a 2×4 (stud actual dimensions are typically approximately 1.5 inch×approximately 3.5 inch). The frame 10 may be set in a larger dimension wall space as needed. Smaller wall cavities may be custom milled per application.

A locking wedge 120 may be provided, as shown in FIG. 5. In this embodiment, the locking wedge 120 is shown at an upper exterior wall of the frame 10; however, alternatively, the locking wedge may be provided at a lower or side exterior wall of the frame 10. In any case, the locking wedge 120 may be provided at an exterior wall opposite to an exterior wall to which the tension plate 30 is attached. The locking wedge 120 may be, for example, an approximately ½ inch tall wedge with a small tooth edge. The small tooth edge allows the locking wedge 120 to lock into the retaining plate(s) 120. The locking wedge 120 may be, for example, formed integrally with the frame 10 or may be welded to the exterior of the frame 10.

One or more hole(s) 140 may be provided in, for example, a side 10c of the frame 10, as shown in FIGS. 1 and 2. Each of the hole(s) 140 may function as a pass through location for, for example, high voltage and low voltage cabling. The cabling may be secured with a threaded clamping device (not shown). One or more cable clamp(s) 180 may be provided as required per building code for high voltage cable management.

One or more AC receptacle(s) 190 may be provided, as shown in FIG. 4. The one or more AC receptacle(s) 190 may be in the form of a standard single gang power receptacle, most commonly referred to as a dual outlet or wall outlet. A single clock style outlet may be acceptable for power as well.

According to one embodiment, the frame 10 may be made of an approximately 1/16 inch to approximately ⅛ inch thick material, such as carbon fiber, aluminum, steel, sheet metal, or another similar or suitable material, depending on a size of the flat panel device to be mounted. As set forth above, the frame may be a solid structure molded, welded, or press formed. The tension plate 30 may be made of an approximately ⅛ inch to approximately ¼ inch thick steel plate to support the weight and stress across the wall studs 110 on which it sits. The adjustment bolt(s) 50 may be approximately ½ inch reverse thread bolts for leveling and tensioning. An approximately ½ inch washer 60 and locking nut 70 may be welded at a top most position of the approximately ½ inch bolt after it is placed though the holes 30a in the frame 10, allowing for proper freedom of the adjustment bolt(s) 50 to spin while tensioning the tension plate 30 below. Approximately 1/16 inch thick channels 40, which may be made of metal, may be welded to the interior of the receiving space of the frame 10 for structural support and may provide upper and lower hanging rail(s) 90 to hold the mounting hook(s) 150a of the mounting rail(s) 150 (attached to a flat panel device 500). Access to cables may be managed in a space between the frame exterior and the hanging rail interior space from either side of the frame to the inside of the frame. A left side of the frame may manage a power source and a right side of the frame may manage all other structured cable audio and video requirements for the flat panel device 500. These channels may be no deeper than approximately ¾ inch to accommodate up to an approximately ½ inch in size cable and connector.

As set forth above, the front of the frame (i.e., the flange) may be capable of being resurfaced with, for example, paint, wood, plastics, and/or other decorative trims to a customer's requirements. Polished or brushed finishes may require treatment of the frame to accomplish a unique look.

The frame may be made available in different sizes to accommodate all sizes of flat panel devices, such as LCD devices, PDP devices, and future OLED devices, with or without attached speakers. For example, one size may hold an approximately 30 inch 16:9 format panel up to an 80 inch 16:9 format panel. The frames may be ordered using, for example, a model number or exact flat panel dimensions. The frame may allow for approximately 1.5 inch of space at all edges of the frame to an outer edge of the flat panel device for heat ventilation. A depth of the frame may allow for a maximum recess of approximately 3.5 inch from a drywall edge to an interior of the wall. Although many models of flat panel devices today have an overall depth of approximately 3.9 inch to approximately 4.5 inch, back and sides of the flat panel device would be sufficiently hidden from view for a clean look, while centering a majority of a weight over supporting lower studs.

One existing issue with prior art mounts is that they require reinforcement of the wall, additional framing, wood backing, and/or other structural changes to attach a flat panel device to a wall. The embodiments disclosed herein provide a mounting solution to center more weight over studs in the wall and retain its position by tightening a tension plate for a locking, snug fit.

FIG. 10 is a flow chart of a method for installing a flat panel device 500 using a system 1 such as that shown in FIGS. 1-9. As shown in FIG. 10, in step S210, a hole of suitable dimension may be cut in a desired location in a desired wall in which the system 1 is to be mounted. This may involve cutting away the drywall (or a like wall surface) and removing small sections of the existing (i.e., metal or wood) studs 110 in any interior wall space. The cut drywall section may be cut approximately 1 inch larger that dimensions of the frame 10. Retainer plate(s) 20 may be mounted to the existing wall studs 110, in step S220.

All electronic wiring may at this point be accessed from either side of the pre-drilled or cut-out wall sections. Power may be run by a professional electrician to a single outlet box provided in the flat panel device 500. All other cables or electronic wiring may be run to an opposite side of the frame 10 to insure there is no signal interference from the AC line or outlet.

Mounting rail(s) 150 may be attached onto the flat panel display 500, in step S230. In step S240, with the frame 10 angled, the tension plate 30 may be balanced on lower retainer plate(s) 20 and any cabling or electronic wiring inserted into the wall. By resting the tension plate 30 on an edge of the cut-out hole, one or two people may run the cabling or electronic wiring through the frame 10 into the provided cable channel(s) 40 through pass-through hole(s) 140 provided in the frame 10. The cable channel(s) 40 may be stuffed with insulation after the cabling or electronic wiring is installed to suppress drafting from fire (see local fire codes for best application). The frame 10 may then be tipped upwards with the tension plate 30 at a bottom most position. In step S250, the frame 10 may be correctly positioned into the wall so that the flange 10b covers the edges of the hole. Then, the adjustment device 45 may be adjusted to level the frame 10 and secure it to the wall, in step S260. Once in place, the tension plate 30 may be adjusted so that the locking wedge 120 touches each stud 110 at a top-most position and for leveling purposes. This allows the frame 10 to be wedged into the hole or opening and then tightened to hold onto the drywall from each side of the frame 10. The flat panel device 500 may be lifted into position to slide onto the hanging rail(s) 90 provided in the receiving space 10a of the frame 10, so that the mounting rail(s) 150 of the flat panel display 500 are mounted onto the hanging rail(s) 90 within the receiving space 10a of the frame 10, and any additional cabling or electronic wiring may be inserted into cabling channel(s) 40, in step S270. All holes may be configured to self seal for fire code purposes. Further, wires may be attached at this point from an underside of the flat panel device 500, with enough slack to hide all connections and cables.

In place of heavy wall reinforcement, installation of the flat panel device mounting system according to embodiments disclosed herein merely requires the cutting away of the drywall (or a like wall surface) and removing small sections of the existing (metal or wood) studs in any interior wall space, which allows the system to securely lock into place with minimal effort. The retaining plates, which may be formed of metal, may be attached to multiple studs top and bottom. The tension plate, which may be provided at an underside of the mount, allows for secure tightening and leveling of the frame. The flange, which may extend around the front exterior of the frame, may provide a finished look for the rough cut opening. Once installed, the clean cable management solution of the disclosed embodiments, in home or office interiors, may eliminate the need for additional framing. The system may provide it's own finished edge with a number of styles and material type options. Further, there is enough space around the flat panel device to allow for proper cooling without the aid of a fan. An optional fan may be used in warmer climate application. Hidden cable path(s) may accommodate multiple inputs and up to a largest input type for an LCD device or PDP device, a VGA computer cable. A universal mounting plate may be provided, designed specifically to work with this frame or to accommodate an existing mount for tilt and pivot requirements. A set size may be provided for each range of flat panel device to keep production costs at a minimum, but not overwhelming a size of the flat panel device being installed.

Locking thread screws may be used for the tension plate of the frame to prevent the frame from becoming loose through vibration (for example, vibration caused by doors closing, hammering on opposite sides of the wall, or construction above or below floors). To set the frame in place, a location may be designated at a proper height based on a consumer's application. Either by contractor or homeowner, a section of wall drywall and studs (non load bearing wall) may be cut approximately 1 inch larger than the dimensions of the frame. All wiring may at this point be accessed from either side of the pre-drilled or cut-out wall sections. Power may be run by a professional electrician to a single outlet box provided in the flat panel device. All other cables or electronic wiring may be run to an opposite side of the frame to insure there is no signal interference from the AC line or outlet. By resting the tension plate on an edge of the cut-out, one or two people may run the cabling or electronic wiring through the frame into the provided cable channel(s) through pass-through holes provided in the frame. The cable channel(s) may be stuffed with insulation after the wires are installed to suppress drafting from fire (see local fire codes for best application). The frame may then be tipped upwards with the tension plate at the bottom-most position. Once in place, the tension plate may be adjusted so that the top locking wedge touches each stud at the top and for leveling purposes. This allows the frame to be wedged into the opening and then tightened from each side of the frame to hold onto the drywall. The mounting rail(s) may be attached to a back of the flat panel device that is being mounted. The flat panel device may then be lifted into position to slide onto the hanging rail(s) provided at the back of the frame. The holes may self seal for fire code purposes. Wires may be attached at this point from an underside of the flat panel device, with enough slack in the cord to hide all connections and cables.

It is estimated that it should take approximately two people no longer than approximately one hour to cut, set, and adjust the mounting system. This may offer a significant reduction in production time from reconstructing and framing exact sizes for recessed applications. It also allows for fixed mounting in walls that can not allow for rear reinforcement by plywood or studs. The cost difference in this application to current man hours and materials needed may be approximately half the cost or better depending on how much finish work is required by other trades in those current installations.

Ultimately, improvements to the design may be made as technology changes to accommodate future display types. This same application may have some use in retrofitting recessed shelving and back box capability for electrical pathways and data junction boxes.

Any reference in this specification to “one embodiment,” “an embodiment,” “example embodiment,” etc., means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the invention. The appearances of such phrases in various places in the specification are not necessarily all referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with any embodiment, it is submitted that it is within the purview of one skilled in the art to effect such feature, structure, or characteristic in connection with other ones of the embodiments.

Although embodiments have been described with reference to a number of illustrative embodiments thereof, it should be understood that numerous other modifications and embodiments can be devised by those skilled in the art that will fall within the spirit and scope of the principles of this disclosure. More particularly, various variations and modifications are possible in the component parts and/or arrangements of the subject combination arrangement within the scope of the disclosure, the drawings and the appended claims. In addition to variations and modifications in the component parts and/or arrangements, alternative uses will also be apparent to those skilled in the art.

Claims

1. A system for mounting a flat panel device on a wall, the system comprising:

a frame having a receiving space configured to receive a flat panel device therein; and

a tension plate attached to the frame that provides for leveling of the frame and retention of the frame in the wall.

2. The system of claim 1, wherein the frame is rectangular in shape.

3. The system of claim 1, wherein the frame is formed of a substantially rigid material.

4. The system of claim 1, wherein the frame is formed of a carbon fiber or a metal.

5. The system of claim 4, wherein the metal comprises steel, aluminum, or a sheet metal.

6. The system of claim 4, wherein the frame is molded, welded, or press formed to form the frame as a solid structure.

7. The system of claim 1, wherein the frame comprises a flange at a front outer edge thereof configured to cover an area of a wall cut for installation of the system.

8. The system of claim 1, further comprising at least one attachment device configured to attach the tension plate to the frame, the at least one attachment device being adjustable to provide for leveling of the frame and retention of the frame in the wall.

9. The system of claim 8, wherein the at least one attachment device comprises:

one or more threaded adjustment bolts configured to mate with one or more threaded holes provided in the tension plate;

one or more corresponding washers provided on the respective adjustment bolt and configured to limit vertical movement of the tension plate; and

one or more corresponding locking nuts configured to retain the connection between the respective adjustment bolt and the tension plate.

10. The system of claim 1, further comprising a plurality of retainer plates configured to be mounted to an existing stud of a wall.

11. The system of claim 10, wherein the plurality of retainer plates are each configured to be mounted to an existing stud of a wall by a plurality of bolts configured to mate with a plurality of receiving holes formed in the respective retainer plate.

12. The system of claim 10, wherein each of the plurality of retainer plates comprises a notch and angle that forms a recess configured to mate with one of the tension plate or a locking wedge provided on an exterior of the frame.

13. The system of claim 1, further comprising:

one or more hanger rails installed within the receiving space; and

one or more mounting rails configured to be attached to a flat panel device, wherein the one or more mounting rails each comprise one or more mounting hooks configured to mate with the one or more hanger rails to mount the flat panel device in the receiving space.

14. The system of claim 13, wherein upper and lower edges of the one or more hanger rails are attached to a rear wall of the receiving space to form a channel configured to receive electronic wirings.

15. The system of claim 1, further comprising:

a locking wedge provided on an exterior wall of the frame opposite to an exterior wall of the frame to which the tension place is attached.

16. The system of claim 1, further comprising at least one j-box.

17. The system of claim 16, further comprising at least one cover configured to be attached to the at least one j-box, the at least one cover having at least one hole for passing electronic cabling therethrough.

18. The system of claim 1, wherein the flat panel device comprises one of a LCD device, a PDP device, or an OLED device.

19. A method of mounting a flat panel device on a wall, the method comprising:

providing a frame having a receiving space configured to receive a flat panel device therein and a tension plate attached to the frame;

inserting the frame into a hole in a wall on which the flat panel device is to be mounted;

adjusting the tension plate to level the frame and retain the frame in the hole; and

mounting the flat panel device in the receiving space.

20. The method of claim 1, further comprising:

attaching a plurality of retainer plates to existing studs of the wall; and

inserting the frame into the wall so that the tension plate is positioned adjacent the plurality of retainer plates.