INSTALLATION SYSTEM AND METHOD FOR MOUNTING DEVICES

Description

RELATED APPLICATIONS

This patent application relates to and claims priority from U.S. Provisional Patent Application No. 63/343,250 entitled “System and Method for Installing Electrical Boxes or Rings” filed May 18, 2022 and is incorporated herein by reference including its specification.

FIELD OF THE INVENTION

The present invention relates generally to a speaker ring installation system. Specific embodiments relate to a means for single users to mount speaker rings and rough-in brackets of various sizes.

BACKGROUND OF THE INVENTION

Most speaker manufacturers sell new construction rough-in brackets that are installed before drywall to reserve the exact spot where the speaker will be installed later. The rings are typically installed by a low voltage contractor during construction. The drywall and or stucco contactor will cut out the drywall around the ring, or stucco up to the ring. This leaves a perfect cut out for the speaker to be installed at the finish phase.

During installation, speaker rings are difficult to align, hold, measure and secure. One hand must hold the ring in place, one hand must measure and line up the ring and the ring still needs to be secured using a drill and screw. This process almost requires “3 hands” or 2 people to do properly. If done incorrectly, the speaker ring may not line up with other devices, or be out of place. This can result in unnecessary repair time and costs to fix speaker rings once the finish work is done. The tool listed herein assists with the installation process, making it much easier and time effective.

Accordingly, there is a need for a system and method for mounting electrical installations that makes it easier for an individual to install the such a mounting system alone or with minimal assistance. The present invention fulfills these needs and provides other related advantages.

The present invention has been developed in response to the present state of the art, and in particular, in response to the problems and needs in the art yet fully solved by currently available speaker installation systems. Embodiments of the disclosure aid and assist with the installation of in-wall and in-ceiling speaker rough-in construction brackets. Rough-in speaker installation systems consist of a speaker ring (or other electrical box/ring) with webbing or wings extending from generally opposite sides thereof. The webbing or wings are sufficiently long such that they can span the distance between adjacent studs or joists while allowing the box/ring to be positioned at virtually any point between the studs or joists.

Embodiments of the disclosure may generally include removable brackets temporarily affixed to faces of wall studs along a designated axis of alignment where such a box or ring is to be mounted. The removable brackets are affixed to the studs using screws or similar fasteners through raised platforms or brackets at each end thereof. The raised platforms or brackets creates a “passthrough” area between the mounting plate and the face of the stud. The passthrough area is sufficiently wide to accommodate the webbing or wings on the box/ring.

Once the webbing or wing(s) have been placed in the passthrough areas of two separate mounting plates, the box/ring to be installed may be positioned at the desired location between adjacent studs. Each removable plate includes a plurality of openings. The openings accommodate nails or similar fasteners that are configured to secure the webbing or wings to the face of the studs without fixing the removable bracket. The openings are sufficiently large such that the nails or similar fasteners pass freely through the mounting plate. Once the webbing or wings are affixed to the studs, preferably by two or more nails or similar fasteners, the screws or similar fasteners can be removed from the mounting plates allowing the mounting plates to be removed.

Embodiments of the disclosure may include a removable bracket configured for engaging an installation web on mounting devices. The first removable bracket may be used in tandem with a second removable bracket. The removable bracket may include a body which has a central mount hole with a first spacer and second spacer oppositely positioned about the mount hole. The spacers define what are “pass through” gaps through which substrate mounting elements can be inserted. A hole generally referred to as a first spacer aperture passes through the first spacer and body of the bracket. Similarly, a second spacer aperture passes through the second spacer and body of the bracket. Fasteners may be applied through the apertures.

The central mount hole provides a guide to locate the center line for orienting the device relative to various installation substrates. The central mount hole is configured to have dimensions greater than corresponding fasteners used with the device. This allows fasteners to pass through the mounting device and still secure the installation systems within. A plurality of ancillary holes about the central mount hole allow greater flexibility in placing such fasteners. The ancillary holes are also configured to have dimensions greater than the corresponding fasteners used with the device.

The mounting device may be fit with a variable spacer configured similarly to the first spacer. The variable spacer may allow the installer to change the width of the “through gap”. A spacer channel along the body allows the variable spacer to slidingly associate with the body thereby enabling variable “through gap” widths.

The installation system may be applied to materials including wall studs and ceiling joists. A method for installing a mounting device using the installation system described above may generally be described as follows. A user may provide at least one removable bracket and an electronics mounting device that has at least one substrate interface. The user may designate an alignment point on a receiving substrate. The alignment point may be aligned with the center line on each removable bracket. The removable bracket is then superposed over the receiving substrate. Then, at least one removeable bracket is removably mounted onto the receiving substrate at the spacers.

At least one substrate is then inserted into at least one “through gap” formed between either the first spacer and second spacer or between a variable spacer and a second spacer. The user then passes at least one fastener though one of a plurality of ancillary holes about the central mount hole on each removable bracket. Each fastener is attached to the receiving substrate. Finally the removable bracket is unmounted at the spacers and the bracket is removed.

The method for using the mounting device may be used in tandem with as many removable brackets with substrate interfaces as required by the user. For example, there may be a first removable bracket and second removable bracket each with a first substrate interface and second substrate interface. The first and second brackets and interfaces may be oppositely disposed about the electronic mounting device to be installed.

Where multiple removable brackets are deployed by a user a first removable bracket may be removably mounted onto a first ceiling joist and a second removable bracket may be removably mounted onto a second ceiling joist. A first substrate may be inserted into the “through gap” formed between the first spacer and second spacer on the first removable bracket. The second substrate interface may be inserted into the through gap formed between the first spacer and second spacer on the second removable bracket. A first fastener may be applied through one of the plurality of ancillary holes about the central mount hole on the first removable bracket and a second fastener through one of the plurality of ancillary holes about the central mount hole on the second removable bracket. The first fastener may be attached to the receiving substrate over which the first removable bracket is superposed through the first substrate interface. The second fastener may be attached to the receiving substrate over which the second removeable bracket is superposed through the second substrate interface. Then the first removable bracket and second removable bracket may be removed.

Other features and advantages of the present invention will become apparent from the following more detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention.

BRIEF DESCRIPTION OF THE FIGURES

These and other features and advantages of the present invention will become appreciated, as the same becomes better understood with reference to the specification, claims and drawings herein:

FIG. 1 is a front perspective view of an embodiment of the disclosure.

FIG. 2 is a back perspective view of the embodiment of FIG. 1.

FIG. 3 is a front perspective view of another embodiment of the disclosure.

FIG. 4 is a process flowchart listing steps of a method for using embodiments of the present disclosure.

FIG. 5 is an embodiment displaying step III of the diagram of FIG. 4.

FIG. 6 is an embodiment displaying step IV of the diagram of FIG. 4.

FIG. 7 is an embodiment displaying step V of the diagram of FIG. 4.

FIG. 8 is an embodiment displaying step VI and VII of the diagram of FIG. 4.

FIG. 9 is an embodiment displaying step VIII of the diagram of FIG. 4.

FIG. 10 is an embodiment displaying step IX of the diagram of FIG. 4.

DETAILED DESCRIPTION

The invention now will be described more fully hereinafter with reference to the accompanying drawings, in which embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.

It will be understood that when an element is referred to as being “on” another element, it can be directly on the other element or intervening elements may be present there between. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

It will be understood that, although the terms first, second, third etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms are only used to distinguish one element, component, region, layer or section from another element, component, region, layer or section.

As used herein, the singular forms “a,” “an,” and “the,” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” “includes” and/or “including,” and “have” and/or “having,” when used in this specification, specify the presence of stated features, regions, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, regions, integers, steps, operations, elements, components, and/or groups thereof.

Furthermore, relative terms, such as “lower” or “bottom,” and “upper” or “top,” and “inner” or “outer,” may be used herein to describe one element's relationship to another elements as illustrated in the Figures. It will be understood that relative terms are intended to encompass different orientations of the device in addition to the orientation depicted in the Figures.

Unless otherwise defined, all terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and the present disclosure, and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

Exemplary embodiments of the present invention are described herein with reference to idealized embodiments of the present invention. As such, variations from the shapes of the illustrations as a result, for example, of manufacturing techniques and/or tolerances, are to be expected. Thus, embodiments of the present invention should not be construed as limited to the particular shapes of regions illustrated herein but are to include deviations in shapes that result, for example, from manufacturing.

The present invention is directed to a novel speaker ring installation system. Embodiments of the device are generally referred to by reference to numeral 1, a removable bracket, as shown in FIGS. 1-9. As shown in FIG. 1 the removable bracket 1 may include a body 21, a first spacer 23, a second spacer 25, a pass-through gap 27, a view port 28 and a plurality of mounting holes 29.

The inventive speaker ring mounting system and components thereof, especially the body 21, may be provided in any size and shape to accommodate any size substrate. Each component may be made of material including plastic, metal, and composites thereof. In preferred embodiments the body 21 and spacers 23 and 25 are comprised of a rigid material.

Embodiments of the invention interact generally with at least one receiving substrate 11 which may include wall or flooring studs or joists and a mounting device 13 which may include rough-in speaker brackets. Such mounting devices 13 may have extensions of wire or mesh or any other material through which a fastener may be driven. Such extensions may be referred to as a stud interface 15.

The body 21 supports the first spacer 23 and second spacer 25 which may interface with a receiving substrate 11. In preferred embodiments the viewport 28 may be centrally positioned about a centerline 35 that divides the body 21 generally in half. The first spacer 23 and second spacer 25 are oppositely disposed about the body 21. The body 21, first spacer 23, and second spacer 25 define the pass-through gap 27.

The first spacer 23 may have a first spacer aperture 31. The second spacer 25 may have a second spacer aperture 33. The apertures may be large enough to accept any fastener such as a nail or preferably a more easily removable fastener such as a screw. Each of the plurality of mounting holes 29 are configured to have a diameter greater than the largest diameter, i.e., head, of a corresponding fastener.

In other embodiments of the disclosure, a variable spacer 37 may replace the first spacer 23 as shown in FIG. 3. The variable spacer 37 slidingly associates with the body 21 allowing a user to alter the distance between the second spacer 25 and variable spacer 37 as needed to accommodate any size substrate interface 15. As shown in FIG. 3, a spacer channel 39 defines the area within which the variable spacer 37 may be repositioned.

A method for installing mounting devices using embodiments of the inventive speaker ring installation system may be observed according to FIG. 4. Generally, one or more brackets are removably installed onto adjacent wall studs or ceiling joists thereby creating a means for suspending wings of a rough-in speaker bracket suitable for use by one operator.

As indicated by FIG. 4, step (i), a mounting device 13 and at least one removable bracket 1 is provided. An operator locates at least one receiving substrate 11 for mounting each removable bracket 1. As shown in FIG. 4, steps (ii) and (iii), an alignment point 51 along an axis generally perpendicular to each receiving substrate 11 is designated and marked. The removable bracket 1 is superposed on the receiving substrate 11 such that the operator can view the alignment point 51 through the view port 28 ensuring that desired placement is maintained as shown in FIG. 6.

As shown in FIG. 6, a fastener is removably applied to the first spacer 23 through the first spacer aperture 31 thereby facilitating attachment of the removable bracket 1 to the receiving substrate 11. A fastener is similarly applied to the second spacer 25 through the second spacer aperture 33 providing a second attachment site as shown in FIG. 7. Additional removable bracket(s) 1 may be similarly applied to additional receiving substrate(s) 11.

As shown in FIG. 7, at least one stud interface 15 may be inserted into at least one passthrough gap 27 of the corresponding removable bracket 1. In preferred embodiments of the disclosure, more than one substrate interface 15 may be inserted into a removable bracket 1 pass through gap 27 as shown in FIG. 8.

As shown in FIGS. 7-10, the passthrough gap 27 created by the first spacer 23 and second spacer 25 allow each stud interface 15 to move freely within the removable bracket 1. The first spacer 23 and second spacer 25 are external to the stud interface 15 such that fasteners applied through a first spacer aperture 31 and second spacer aperture 33 do not fix the stud interface 15. This provides ease of mounting device 13 through the installation and repositioning of the mounting device 13, particularly the center-line 13a, aligned with middle-line 53 between adjacent receiving substrates 11 prior to permanent fixation

Once the mounting device 13 is disposed in the desired position relative to the receiving substrate(s) 11, each stud interface 15 may be secured to each receiving substrate 11 as shown in FIG. 9. At least one fastener is applied to at least one of the plurality of mounting holes 29 thereby securing the stud interface 15 to the receiving substrate 11. The plurality of mounting holes 29 are configured to be larger than a corresponding fastener. This relative size allows the mounting device 13 to remain secured to the receiving substrate 11 when the removable bracket 1 is unmounted from the same.

Once all desired fasteners are applied, an operator may remove fasteners from any first spacer aperture 31 and second spacer aperture 33 as shown in FIG. 10. This accordingly unmounts any removable brackets 1 leaving undisturbed any mounting devices 13.

Other embodiments of the description may have the variable spacer 37 in lieu of the first spacer 23 as shown in FIG. 3. The variable spacer 37 better accommodates mounting devices 13 and stud interfaces 15 of varying sizes. The variable spacer 37 may slidingly associate with the body 21 of the removable bracket 1 along the variable aperture 39. Once a desired distance between the variable spacer 37 and second spacer 25 is achieved, an operator may secure the variable spacer 37 to the receiving substrate 11. This is done by applying a fastener at a variable aperture 39 through the body 21 and variable spacer 37. Alternatively, the variable spacer 37 may be provided in addition to both the first spacer 23 and second spacer 25. Although not shown in these figures, the variable spacer 37, includes guides or similar structures to prevent undesired rotation of the variable space 37 relative to the body 21 of the removable bracket 1. In this context, undesired rotation refers to keeping the variable spacer 37 generally perpendicular to the variable aperture 39. The removable bracket 1 with variable spacer 37 may be unmounted in the same manner as described above.

Although several embodiments have been described in detail for purposes of illustration, various modifications may be made without departing from the scope and spirit of the invention.