Adapter for mounting a faceplate of a first style on to an electrical outlet cavity of a second style

FIELD OF THE INVENTION

The present invention relates to a mechanical mounting adapter for electrical fixtures and the like, and, more particularly, to a wall mounting adapter for outlets and similar fixtures.

BACKGROUND OF THE INVENTION

Wall outlets for electrical apparatus and the like are in widespread use, allowing convenient connection of devices such as electrical appliances, telephones, cable television receivers, and computers to electrical power mains and communication networks. In addition, similar fixtures are often attached to walls, floors, and ceilings, and are connected in like manner to electrical power and communications networks. The term "wall" herein denotes any fixed surface to which socket outlets are commonly connected and includes, without limitation, walls of a building or similar structure regardless of orientation (including, but not limited to vertical walls, as well as floors and ceilings), as well as surfaces of other structures to which socket outlets may be fixed, such as cupboards and desk tops particularly when fixedly mounted in a room. Likewise, the term "outlet" herein denotes a non-limiting instance of a fixture for attachment to a wall or other fixed structure, enabling access to in-wall wiring, commonly via faceplate panel connector. Other fixture types include, but are not limited to, wall-mounted electrical lighting and appliances, controls, switches, sensors, data devices, telephony equipment, and intercommunication devices. Outlets commonly uses in-wall dedicated cavity, but some types are surface-mount, fully installed over the wall surface.

Outlets commonly comprise two distinct parts: <ol id="ol0001" compact="compact" ol-style=""><li><b>(a) Faceplate.</b> The outer part of the outlet, commonly formed of plastic and comprising a front panel accommodating a standard connector for connecting to the in-wall wiring. The front panel of the faceplate is usually decorative, being the only exposed outlet part after the installation.</li><li><b>(b) Wall mounting fixture.</b> This fixture is mechanically attached to the wall on the wall inner side, and is attached to the faceplate on the wall outer side thereby fixing the outlet to the wall. Commonly, the faceplate is attached to the wall-mounting fixture be means of two screws.</li></ol>

There are two principal outlet types that are in common use, depending on the style of wall construction and the opportunities consequently available for mechanically attaching fixtures to a wall and providing electrical or signal connections thereto.

One such wall mounting fixture system is the "junction box" style as illustrated in <figref idref="f0001">Figure <b>1</b></figref><b>.</b> The junction box style is common in North America and is used with a hollow wall construction in which a wall section <b>101</b> is held in place and supported by a support beam <b>103,</b> wherein such support beams are placed at suitable intervals. Typically, wall section <b>101</b> may be a relatively thin panel of gypsum or other material (approximately 3.81 centimeters, which are equivalent to one-half inch thick), and the support beam <b>103</b> is usually of wood or metal. A rectangular junction box <b>105</b> is securely fastened to the support beam <b>103,</b> but may alternatively be affixed to any other suitable supporting structure. The junction box <b>105</b> has an open face <b>107,</b> which is exposed through a matching opening cut into the wall section 101. Commonly, the junction box <b>105</b> is made of metal or plastic, although other suitable materials may be employed. Mounting tabs <b>109-a</b> and <b>109-b</b> are provided on opposing sides of the face <b>107</b> and accommodate threaded mounting holes <b>111-a</b> and <b>111-b</b> allowing the attachment of various electrical fixtures to the junction box <b>105.</b> It is to be noted that the nominal center distance between the mounting holes <b>111-a</b> and <b>111-b</b> is substantially 8.255 centimeters (3¼ inches). Media <b>113</b> enters the junction box <b>105,</b> optionally via a conduit (not shown), which connects to the junction box <b>105</b> in one of several optional apertures (not shown) in the closed faces. Media <b>113</b> can carry electrical power, telephony signals, or other signals for sensing, data, or control. Any number of media <b>113</b> can be used, and can include different combinations and configurations of electrical conductors, such as wires or coaxial cable; or non-conducting media, such as optical fiber.

<figref idref="f0002">Figure <b>2</b></figref> illustrates how a faceplate <b>201</b> (or similar fixture) is mounted according to the junction box system (wall section <b>101</b> in <figref idref="f0001">Figure <b>1</b></figref> is omitted for clarity). Screws <b>203-a</b> and <b>203-b</b> affix faceplate <b>201</b> to junction box <b>105</b> through the mounting holes <b>111-a</b> and <b>111-b,</b> respectively. Because junction box <b>105</b> is secured to the support beam <b>103</b> (or other suitable supporting structure), the faceplate <b>201</b> is thereby securely fastened in place. Faceplate <b>201</b> comprises two telephony connectors (such as RJ-11 ), connected to in-wall telephone wiring, hence being part of telephone outlet. As can be seen in <figref idref="f0002">Figure 2</figref>, the faceplate <b>201</b> is designed to be coupled to the wall mounting fixture <b>105,</b> by means of mechanical size and rectangular shape, intended to cover all fixture <b>105</b> cavity, and holes matched for screws <b>203</b> to fit threads <b>111</b>.

The second commonly used wall mounting method is the "cylindrical cavity and sleeve" style as illustrated in <figref idref="f0003">Figure <b>3</b></figref><b>.</b> The cylindrical cavity and sleeve style is common in Europe and the Middle East and is used with a construction in which a wall section <b>301</b> is made of solid, or substantially solid masonry or similar rigid material which is self-supporting and requires no additional structural elements for stability. A cylindrical cavity 303 is formed in the wall section 301, and an optional sleeve 305 is inserted therein from the outside. The sleeve 305 is commonly of plastic or other semi-flexible material, and typically is in the shape of a cup with a lip and closed back. The sleeve 305 may also have mounting screws (not shown) for affixing to the wall section <b>301.</b>

<figref idref="f0004">Figure <b>4</b></figref> shows a prior art wall mounting fixture device <b>401</b> for the cylindrical cavity and sleeve style of wall mounting. A pair of expandable clamps <b>403-a</b> and <b>403-b</b> is positioned to grip the inside of the sleeve <b>305</b> (<figref idref="f0003">Figure <b>3</b></figref>)<b>,</b> or alternatively the inside of the cavity <b>303</b> if no sleeve <b>305</b> is present. Cavities are typically cylindrical with an inside diameter of approximately 5.5 centimeters, but other cavity shapes and sizes are in general also possible. Clamp 403-a can be expanded outward to engage a grip on the inside of sleeve <b>305</b> (and subsequently increase the grip strength) by tightening a screw <b>405,</b> and clamp <b>403-b</b> can likewise be expanded outward for this purpose by a similar screw (not shown). It is also possible to use a single expandable clamp in conjunction with a fixed clamp or similar projection that is capable of gripping the inner surface of sleeve 305 or the inside of cavity <b>303</b> if no sleeve <b>305</b> is present. Once the wall mounting fixture device 401 has been secured inside the cavity 303, the faceplate (not shown) may be fastened to attachment device 401 by means of screws driven into mounting holes 407-a and 407-b. It is to be noted that the nominal center distance between mounting holes <b>407-a</b> and <b>407-b</b> is six (<b>6.0</b>) centimeters (approximately <b>2.36</b> inches). The faceplate is also well suited to the wall mounting fixture, being of square shape, and having screw holes suitable for affixing the faceplate into the wall mounting fixture.

It is further noted that: <ul id="ul0001" list-style="none" compact="compact"><li>□ the prior art wall mounting fixture device as illustrated in <figref idref="f0004">Figure <b>4</b></figref> and described herein is capable of mounting substantially all commonly-used fixtures and outlets intended for cylindrical cavity and sleeve wall mounting;</li><li>□ all variations in the design and configuration of such prior art wall mounting fixture devices are minor, so that all such prior art wall mounting fixture devices are substantially identical in appearance, use, and function;</li><li>□ wall mounting fixtures and faceplates designed for the junction box style of wall mounting are incompatible with, and cannot be mounted in; cylindrical cavity and sleeve construction using the available prior fixture attachment devices (as illustrated in <figref idref="f0004">Figure <b>4</b></figref> and as described herein); and</li><li>□ no means of readily mounting fixtures and outlets designed for the junction box style of wall mounting is currently available for cylindrical cavity and sleeve construction.</li></ul>

All common fixture and outlet types (such as electrical power outlets, telephone jacks, and lighting fixtures) are widely available for both of the above wall mounting styles. Thus, regardless of which style of wall mounting is employed within a building, it is easy to obtain these common fixtures and outlet types for that wall mounting style.

Many specialized fixtures and outlets, however, are now becoming available for specific purposes. Non-limiting examples of such specialized fixtures and outlets include outlets for data networking, multi-media, sensors, control units, and the like. Such fixtures and outlets may not be readily available for both wall mounting styles. In general, such specialized wall mounting fixtures and faceplates tend to be available for the wall mounting style that is prevalent in the region where their most important market is located. In particular, because of the size and importance of the North American market, most such specialized wall mounting fixtures and faceplates tend to be available primarily for the junction box style of wall mounting, as illustrated in <figref idref="f0001">Figure <b>1</b></figref> and <figref idref="f0002">Figure <b>2</b></figref><b>.</b> In many cases, such specialized wall mounting fixtures and faceplates are not available for the cylindrical cavity and sleeve style. Where this is the case, specialized wall mounting fixtures and faceplates cannot easily be installed in buildings whose construction utilizes the cylindrical cavity and sleeve style of wall mounting without expensive and unsightly external retrofitting of junction boxes <b>105</b> within the smaller cavities <b>303</b> provided for the sleeves <b>305,</b> and therefore the utility provided by such specialized wall mounting fixtures and faceplates is difficult and expensive to provide for those buildings.

<patcit id="pcit0001" dnum="US6184468B"><text>US 6,184,468 (Speziale) published Feb. 6,2001</text></patcit> and entitled <i>"Electrical box with semi-attached adaptor"</i> discloses an electrical housing assembly adapted to be affixed behind a finished surface such as a wall or ceiling and designed to receive an electrical device which will be exposed outwardly from the finished surface. The housing assembly comprises an electrical box which has an open side to permit an electrician to easily inspect or conduct work on the wiring contained within the housing. The electrical box includes punch-outs which permit external wiring to be inserted within the box opening. A frame-shaped flat adaptor which is designed to affix an electrical device thereto is attached to the electrical box by a hinge assembly which permits the adaptor to remain coupled to the electrical box in both a closed position and an open position. A fastener, such as a snap-on clip, secures the adaptor to the electrical box in the closed position when desired by the electrician, but is also easily detachable.

<patcit id="pcit0002" dnum="DE4311137"><text>DE 43 11 137 published Oct. 6, 1994</text></patcit> and entitled <i>"Communications plug socket having an adaptor for use with any desired ranges of domestic service appliances"</i> discloses a communications plug socket, consisting of a base having load bearing elements and a covering plate which, by means of an adaptation, enables installation in any desired range of domestic service appliances and provides marking (designation) of the communications plug socket.

<patcit id="pcit0003" dnum="WO9854806A"><text>WO 98/54806 published Dec. 3, 1998</text></patcit> and entitled <i>"Flush Mounted Metal or Plastic Box"</i> discloses a flush mounted metal or plastic box having its own fixing system adapted to the function required by the user, in particular in the building sector as complement or component in any electrical or non-electrical unit (appliance) to be flush mounted or already flush mounted.

<patcit id="pcit0004" dnum="DE29907456U"><text>DE 299 07 456 U</text></patcit> to Gebr. Berker GmbH &amp; Co, published 29 July 1999 describes a two-piece adapter for attaching an electrical faceplate switch to an outlet wall box using nuts and bolts.

There is thus a widely recognized need for, and it would be highly advantageous to have, an adapter which provides easy installation of faceplates designed for the junction box style of wall mounting in buildings whose construction utilizes the cylindrical cavity and sleeve style of wall mounting. More generally, there is a need for an adapter allowing a faceplate of one style to be installed in a cavity suitable for another distinct style. This goal is met by the present invention.

SUMMARY OF THE INVENTION

The present invention provides an adapter that permits mounting a fixture or outlet designed for the junction box style of wall mounting to be installed in a cylindrical or other shaped cavity, with or without a sleeve.

The adapter according to the present invention readily installs into a wall cavity with or without a sleeve, and accepts the attachment of a fixture or outlet designed for the junction box style of wall mounting.

Therefore, according to the present invention there is provided an adapter for mounting a faceplate of a first style constructed to be fixedly attached to a mating outlet cavity by a first fixture device, on to an outlet cavity constructed for mounting thereon another faceplate of a second style via a second fixture device, the adapter comprising: <ul id="ul0002" list-style="none" compact="compact"><li>a first fastener for fixedly attaching the faceplate to the adapter,</li><li>a second fastener for fixedly attaching the adapter to the outlet cavity,</li></ul>

The adapter comprises a single plate having an opening for passing therethrough media for connecting to at least one connector mounted in said faceplate of a first style, and the first and second fasteners are fixed to the plate, and wherein said first fastener is different from said second fastener.

Preferably, a pair of spaced apart mounting points are provided in the plate separated by a distance of substantially 8.255 centimeters (3¼ inches), conforming to the mutual separation between corresponding mounting holes of commercially available junction box faceplates.

BRIEF DESCRIPTION OF THE DRAWINGS

In order to understand the invention and to see how it may be carried out in practice, a preferred embodiment will now be described, by way of non-limiting example only, with reference to the accompanying drawings, in which: <ul id="ul0003" list-style="none" compact="compact"><li><figref idref="f0001">Figure <b>1</b></figref> illustrates the prior art junction box style of wall mounting fixture.</li><li><figref idref="f0002">Figure <b>2</b></figref> illustrates the prior art installation of a faceplate onto a junction box style wall mounting fixture.</li><li><figref idref="f0003">Figure 3</figref> illustrates the prior art cylindrical cavity and sleeve style of wall mounting cavity.</li><li><figref idref="f0004">Figure <b>4</b></figref> illustrates a prior art wall mounting fixture device for the cylindrical cavity and sleeve style.</li><li><figref idref="f0005">Figure <b>5</b></figref> illustrates an adapter according to the present invention for installing a faceplate designed for the junction box style to a wall mounting fixture in a cylindrical cavity.</li><li><figref idref="f0006">Figure <b>6</b></figref> illustrates the installation of a outlet faceplate onto an adapter according to the present invention into a cylindrical cavity sleeve.</li><li><figref idref="f0007">Figure <b>7</b></figref> illustrates an embodiment of the present invention having boxed sides and mounting posts.</li></ul>

DETAILED DESCRIPTION OF THE INVENTION

The principles and operation of an adapter according to the present invention may be understood with reference to the drawings and the accompanying description, wherein components that are common to different embodiments are referenced by identical reference numerals.

<figref idref="f0005">Figure <b>5</b></figref> illustrates an adapter <b>501</b> having a rectangular plate <b>503</b> with an opening <b>505</b> for passing media <b>113</b> (<figref idref="f0003">Figure <b>3</b></figref>) therethrough and having expandable clamps <b>403-a</b> and <b>403-b</b> for gripping to the interior surface of a wall cavity or sleeve. A screw <b>405</b> expands clamp <b>403-a,</b> and a similar screw (not shown) expands clamp <b>403-b.</b> Mounting points <b>507-a</b> and <b>507-b</b> permit attachment of a faceplate (constituting a first faceplate) designed for the junction box style (constituting a first style) of wall mounting. Accordingly, the nominal center distance between mounting points <b>507-a</b> and <b>507-b</b> is substantially 8.255 centimeters (3¼ inches). Non-limiting examples of mounting points <b>507-a</b> and <b>507-b</b> include holes and posts, which may be threaded as well as friction or snap-fit.

<figref idref="f0006">Figure <b>6</b></figref> illustrates the mounting of a faceplate <b>601</b> designed for junction box style mounting on to adapter <b>501,</b> which inserts into sleeve <b>305</b> and attaches therein with clamps <b>403-a</b> and <b>403-b</b> when the respective screws <b>405</b> are tightened (for clarity, wall section <b>301</b> is not shown). Having thus been securely fastened, the adapter <b>501</b> is then ready for the mounting of faceplate <b>601</b> against the rectangular plate <b>503.</b> Faceplate <b>601</b> has mounting holes <b>603-a</b> and <b>603-b,</b> into which screws <b>605-a</b> and <b>605-b,</b> respectively, are passed and affixed into mounting points <b>507-a</b> and <b>507-b,</b> respectively, which may for example be threaded screw holes. Prior to mounting, media <b>113</b> is passed through opening <b>505</b> for connection to an appropriate device (not shown) fixed within the faceplate <b>601.</b>

In the manner illustrated in <figref idref="f0006">Figure <b>6</b></figref> and described above, a customized faceplate designed for junction box mounting can be flush mounted neatly and easily on a wall featuring the cavity and sleeve style of wall mounting.

Faceplate <b>601</b> as illustrated in' <figref idref="f0006">Figure <b>6</b></figref> has a raised body intended for surface mounting on a wall such that the plate <b>503</b> mounts flush against the wall. An alternative embodiment of the present invention, however, is for mounting faceplates and other fixtures intended for mounting inside a junction box. <figref idref="f0007">Figure <b>7</b></figref> illustrates such an adapter wherein the plate <b>503</b> shown in <figref idref="f0006">Figure <b>6</b></figref> serves as a back plate supporting around a perimeter thereof a generally boxlike construction comprising outer sides 703 forming a junction box, and accommodating therein mounting points 705-a and 705-b in the form of raised posts. The raised posts have a threaded bore for threadably attaching the faceplate <b>601</b> thereto. The outer sides <b>703</b> are positioned so that when mounted, the adapter gives an appearance of a junction box flush to the wall. Outer sides <b>703</b> can be made with a variety of heights, so that a shallow and more attractive junction box is possible.

While the invention has been so far described with respect to a rectangular, junction-box style faceplate mounted into circular wall cavity, it will be appreciated that the invention can be equally applied to any case wherein a faceplate of one style is required to be mounted on to an outlet cavity conforming to a different style.

Likewise, while the invention has been described with respect to a limited number of embodiments, it will be appreciated that many variations, modifications, and other applications of the invention may be made. All such embodiments are contemplated as fall within the scope of the appended claims.

Thus, for example, although a pair of spaced apart clamps is shown in <figref idref="f0006">Figures <b>6</b></figref> and <figref idref="f0007"><b>7</b></figref> for fixing the adapter to the outlet cavity or sleeve, it will be appreciated that other means of attachment are possible. For example, an aperture may be formed in the plate 503 at a location that falls within the circumferences of the cavity <b>303</b> or the sleeve <b>305,</b> thus allowing the plate to be screwed to the wall <b>101</b> through the cavity <b>303</b> or the sleeve <b>305.</b> Likewise, in <figref idref="f0007">Figure <b>7</b></figref><b>,</b> the clamps are interconnected by an armature shown as <b>707</b> and having a central aperture <b>709,</b> thus again allowing the plate to be screwed to the wall <b>101</b> through the cavity <b>303</b> or the sleeve <b>305</b> and obviating the need for the clamps.

The faceplate <b>601</b> shown in <figref idref="f0006">Figure <b>6</b></figref> includes a pair of apertures <b>606-a</b> and <b>606-b</b> each for accommodating a respective connector. Such connector can include a telephone connector, a power /electricity connector or a CATV connector. In the case that the faceplate <b>601</b> accommodates multiple apertures (which is not mandatory), the apertures may, if desired, by of different contours so as to allow different types of connector to be mounted therein. By such means, for example, a telephone connector and a computer data connector can be accommodated in the same connector and connected to appropriate media, the faceplate <b>601</b> being fixed to the cavity <b>303</b> or to the sleeve <b>305</b> via the adapter <b>501</b> or <b>701.</b>