Device mounting system

Abstract

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 and a device can. The mounting ring is installed directly into a hole cut at a selected location in the wall or ceiling or into a pre-construction bracket arranged in the wall or ceiling. The device can is later inserted into the mounting ring and retained therein by a combination of a number of magnets that are attracted to a mounting ring flange and a number of spring clips that engage an inner face of a mounting ring body.

Claims

1. A mounting system for mounting a device in a wall or ceiling, comprising: a mounting ring configured to be retained in a hole in a surface of the wall or ceiling, the mounting ring including a mounting ring body having an inner surface that defines a hollow cavity, and a mounting ring flange that extends from the mounting ring body; and a device can configured to be inserted into the mounting ring, the device can including a device can body sized to fit within the hollow cavity defined by the mounting ring body, device internals configured to provide a device function, one or more first spring clips, and a device can flange that extends from the device can body and is configured to engage the mounting ring flange, wherein the device can is retained within the mounting ring by a combination of magnetic attraction between the device can flange and the mounting ring flange and spring force of the one or more first spring clips.

2. The mounting system of claim 1, wherein the one or more first spring clips are affixed to the device can body and extend from an exterior surface thereof to engage the inner surface or a top rim of the mounting ring body.

3. The mounting system of claim 1, wherein the mounting ring flange includes a ferromagnetic metal, and the mounting system further comprises: one or more magnets disposed in the device can flange that magnetically attract the ferromagnetic metal of the mounting ring flange.

4. The mounting system of claim 1, wherein the device comprises an active or a passive speaker, and the device internals comprise at least a speaker cone and a voice coil.

5. The mounting system of claim 4, further comprising: a grille that covers at least a portion of the device can, wherein the grille includes one or more pieces of ferromagnetic metal that are magnetically attracted to the one or more magnets in the device can flange, and wherein the one or more magnets disposed in the device can flange both serve to retain the device can within the mounting ring and retain the grille to the device can.

6. The mounting system of claim 1, wherein the device comprises at least one of a light fixture, a camera, a smoke detector or a carbon monoxide detector.

7. The mounting system of claim 1, wherein the mounting ring is configured to be retained directly in a hole in the wall or ceiling surface.

8. The mounting system of claim 7, wherein the mounting ring flange is configured to engage an exterior face of the wall or ceiling surface, and the mounting system further comprises one or more second spring clips affixed to the mounting ring body and that extend from an exterior surface thereof to engage an interior face of the wall or ceiling surface, wherein the mounting ring is configured to be retained in the hole in the wall or ceiling surface by pinching action caused by the one or more second spring clips.

9. The mounting system of claim 1, further comprising: a pre-construction bracket disposed in the wall or ceiling, wherein the mounting ring is configured to be retained within the pre-construction bracket.

10. The mounting system of claim 9, further comprising: one or more second spring clips affixed to the mounting ring body and that extend from an exterior surface therefrom to engage at least in part the pre-construction bracket, wherein the mounting ring is configured to be retained in the pre-construction bracket in in the wall or ceiling by pinching action caused by the one or more second spring clips.

11. The mounting system of claim 1, wherein the mounting ring body and the device can body are both substantially cylindrical and the mounting ring flange extends radially at an end of the mounting ring body, and the device can flange extends radially from an end of the device can body.

12. A device mounting system for mounting a device in a wall or ceiling, comprising: a mounting ring configured to be retained in a hole in a surface of the wall or ceiling, the mounting ring having a mounting ring flange; a device can that holds device internals configured to provide a device function, the device can configured to be inserted into the mounting ring, the device can including a device can flange configured to engage the mounting ring flange; one or more magnets disposed in the device can flange, and one or more first spring clips, wherein the device can is retained within the mounting ring by a combination of magnetic attraction between the device can flange and the mounting ring flange produced by the one or more magnets and spring force produced by the one or more first spring clips.

13. The mounting system of claim 12, wherein the device comprises a passive or an active speaker, and the device internals comprise at least a speaker cone and a voice coil.

14. The mounting system of claim 13, further comprising: a grille that covers at least a portion of the device can, wherein the one or more magnets both serve to retain the device can within the mounting ring and to retain the grille to the device can.

15. The mounting system of claim 12, wherein the device comprises at least one of a light fixture a camera, a smoke detector or a carbon monoxide detector.

16. The mounting system of claim 12, wherein the mounting ring is configured to be retained directly in a hole in the wall or ceiling surface.

17. The mounting system of claim 12, wherein the mounting ring is configured to be retained within a pre-construction bracket that disposed in the wall or ceiling.

18. The mounting system of claim 12, wherein the mounting ring and the device can are both substantially cylindrical.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The description below refers to the accompanying drawings of example embodiments, of which:

(2) FIG. 1 is a perspective view depicting an example device mounting system in an embodiment where the device is an active speaker;

(3) FIG. 2 is a front view depicting the example device mounting system of FIG. 1;

(4) FIG. 3 is a top view of a device can of the example device mounting system of FIG. 1,

(5) FIG. 4 is a top view of a mounting ring of the example device mounting system of FIG. 1;

(6) FIG. 5 is a bottom view of the device can of the example device mounting system of FIG. 1;

(7) FIG. 6 is a bottom view of the mounting ring of the example device mounting system of FIG. 1;

(8) FIG. 7 is an example grille that may cover the bottom of the device can in an embodiment where the device is a speaker;

(9) FIG. 8 is a perspective view depicting an example device mounting system employed in an embodiment where the device is a passive speaker;

(10) FIGS. 9a-9c are perspective views depicting an example mounting system employed in embodiments where the device is a light fixture, specifically a flood (9a), spot (9b) or wall washer (9c);

(11) FIG. 10 is a perspective view depicting an example device mounting system employed in an embodiment where the device is a camera;

(12) FIG. 11 is a perspective view depicting an example device mounting system employed in an embodiment where the device is a combined smoke and carbon monoxide detector;

(13) FIG. 12 is a perspective view depicting an example pre-construction bracket that may be used with an example device mounting system; and

(14) FIG. 13 is a perspective view depicting an example mud housing and mud ring that may be attached to an example pre-construction bracket to enable a flush-mount installation.

DETAILED DESCRIPTION

(15) Referring to FIGS. 1-6, an example device mounting system 100 is shown for an embodiment where the device is an active speaker. The system 100 includes a mounting ring 110 and a device can (e.g., speaker can) 120. The mounting ring 110 includes a substantially cylindrical mounting ring body 130 that defines a hollow cavity and a mounting ring flange 135 that extends radially therefrom, at its bottom end. The mounting ring body 130 and mounting ring flange 135 may be integrally formed from a piece of ferromagnetic metal (e.g., steel). Alternatively, the mounting ring body 130 and mounting ring flange 135 may be separate components that are joined together. In such cases, just the mounting ring flange 135 may be made from a ferromagnetic metal (e.g., steel) and the body may be made from another material. A number of (e.g., 4) spring clips 140 are affixed to an exterior surface of the mounting ring body 130. The spring clips may be slidably-affixed to the mounting ring body 130 by a slotted-connection where an inner portion of the spring clips 140 are woven through slots formed in the mounting ring body 130. The slotted-connection may allow for the spring clips 140 to have vertical travel through a range of motion, to facilitate easier installation and to accommodate different thicknesses of a wall or ceiling surface (e.g., different thicknesses of drywall) and pre-construction brackets when installed. Alternatively, the spring clips 140 may be rigidly affixed to the mounting ring body 130, for example, using fasteners (e.g., rivets, screws, etc.). An outer portion of the spring clip 140 may include a back-bent portion 145. The spring clips 140 may be made from a material that returns to its original shape after significant deflection, such as spring steel.

(16) 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.

(17) 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 FIG. 12, the pre-construction bracket 1200 includes a pre-construction bracket body 1220 and wings 1210. The pre-construction bracket 1220 it retained by attachment of the wings 1210 by fasteners (e.g., nails) to studs or joists prior to the surface (e.g., the drywall) being added to the wall or ceiling. In some installations, the pre-construction bracket 1200 may be used as a guide to cut a hole in the surface (e.g., the drywall) of the wall. After the surface (e.g. drywall) is in place, the mounting ring 110 is inserted into a hole defined by the pre-construction bracket. In a flush-mount installation, the pre-construction bracket may be used in combination with a mud housing 1310 and a mesh mud ring 1320. The mud housing 1310 may be attached to the preconstruction bracket prior to installation of the wall or ceiling surface (e.g., drywall), and the surface (e.g., drywall) installed up to the housing. The mud ring 1320 may be attached thereto, and plaster or compound applied.

(18) 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.

(19) 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.

(20) Referring to FIG. 7, for an embodiment where the device is a speaker such as the active speaker shown in FIGS. 1-6, a grille or faceplate 170 may be provided. The grille or faceplate 170 may have a diameter slightly smaller than raised lip 157, such that when affixed to the device can flange 155, it fits within the lip 157. The grille 170 may be made of a fabric material stretched over a frame. A number of pieces of ferromagnetic metal (steel) may be disposed in the frame at locations coinciding with the magnets 160.

(21) 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).

(22) 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 FIGS. 1-6, a speaker cone, surround, and dust cap 159 (see FIG. 5) may be disposed on the bottom face of the device can body 150, and driven by a voice coil and speaker magnet (not shown) mounted inside the device can body 150. In an active speaker embodiment, the device internals may also include an active crossover component and amplifier assembly 175 including a power over Ethernet (POE) port 185. In other embodiments, the device internals may take other forms. Referring to FIG. 8, in an embodiment where the device is a passive speaker that lacks amplification capabilities, the device internals may include a passive speaker back assembly 177 including speaker level audio via ports 190. Referring to FIGS. 9a-9c, in an embodiment where the device is a light fixture, the device internals may include a flood light element (e.g., a light-emitting diode (LED) flood light bulb) 910, a spot light element (e.g., a LED spot light bulb) 920, or a wall washer element (e.g., a LED bulb in a directional mounting) 930. Referring to FIG. 10, in an embodiment where the device is a camera 1000, the device internals may include lenses, image sensors and supporting electronics. Referring to FIG. 11, in an embodiment where the device is a combined smoke and carbon monoxide detector 1100, the device internals may include a LED and photocell for performing optical smoke detection, an ionization chamber and electrodes for performing ionization based smoke detection, a metal oxide semiconductor or electrochemical sensor for performing carbon monoxide detection, an alarm speaker, as well as other supporting electronics and connections. It should be understood that a wide variety of other devices may alternatively make use of the device mounting system 100, and that the device internals may take a wide number of different forms.

(23) 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.

(24) 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.

(25) 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.

(26) 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.

(27) 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.

(28) 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.

(29) 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.

(30) Above all, it should be understood that the above embodiments are meant to be taken only by way of example.