US20100050538A1

US20100050538A1 - Mounting system with component and cover plates

Info

Publication number: US20100050538A1
Application number: US12/555,534
Authority: US
Inventors: Scott Struthers; Ray Call
Original assignee: Dana Innovations Inc
Current assignee: Dana Innovations Inc
Priority date: 2006-12-04
Filing date: 2009-09-08
Publication date: 2010-03-04
Also published as: WO2011031633A1

Abstract

Mounting systems are described for installing components in walls or other structural barriers. A preferred mounting system has a rear bracket and a component holder that supports the component, and that cooperate with each other to sandwich the structural barrier. An intermediate piece mates with the component holder, and has a hole through which a portion of the component can extend. A cover mates with the component holders, and is preferably recessed within the intermediate piece such that the outward facing surface of the cover is flush with a spackle rim.

Description

This application is a continuation-in-part of non-provisional application Ser. No. 12/427,591 filed Apr. 21, 2009 which is a continuation-in-part of non-provisional application Ser. No. 12/202,870 filed Sep. 2, 2008 which is a continuation-in-part of non-provisional application Ser. No. 11/954,667 filed Dec. 12, 2007, Issued U.S. Pat. No. 7,461,483 which is a continuation-in-part of non-provisional application Ser. No. 11/566,365 filed Dec. 4, 2006 and claims priority to provisional application Ser. No. 60/950,237 filed Jul. 17, 2007 and is a continuation-in-part of International application Ser. No. PCT/US07/16404 filed Jul. 19, 2007 which claims priority to 60/258,162 filed Sep. 11, 2006, non-provisional application Ser. No. 11/548,381 filed Oct. 11, 2006, and 60/950,237 filed Jul. 17, 2007. All prior applications are incorporated by reference in their entirety.

FIELD OF THE INVENTION

The field of the invention is wall mount coverings.

BACKGROUND

Mounted components, including for example, plasma screens, speakers, power outlets, air vents, electrical outlets, recessed lighting, fire sprinklers, cameras, junction boxes, have all been mounted in various ways to walls, ceilings or other structural barriers. Such components can generally be divided into eight distinct categories: speakers, lighting, controllers, air vents, power/data interfaces, fire response devices, cabinetry, and cameras. Since companies typically only make components that fall into one category, buildings with components from different categories tend to require disparate mounting systems to install the components to the structural barriers. These disparate mounting systems increase the time and complexity of installation, and the installed components often have a disjointed look and feel. For example, lighting installed in a ceiling generally requires a different mounting system than a power outlet installed in a wall.
While various mounting systems are known, such systems typically permit the installation of only a single component type due to size and dimension limitations. For example, U.S. Pat. No. 5,736,574 to Gretz discusses an electric box extender that is used only for the installation of electrical outlets. This is problematic, as the Gretz device necessitates the use of other mounting products for the installation of different components, and therefore suffers from the problems discussed above. Gretz and all other extrinsic materials discussed herein are incorporated by reference in their entirety. Where a definition or use of a term in an incorporated reference is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein applies and the definition of that term in the reference does not apply.
Thus, there is still a need for systems of installing components to structural barriers such that a variety of components could be installed using the same system.

SUMMARY OF THE INVENTION

The inventive subject matter provides apparatus, systems and methods in which a mounting system is used for installing a component in a structural barrier. As the terms are used herein, “controller” includes any device that sends commands to another device, and “fire response devices” include both fire alarms and fire sprinklers.
Preferred mounting systems include a rear bracket and a component holder. The component holder supports a component and cooperates with the rear bracket to sandwich a structural barrier. The mounting systems also include an intermediate piece that mates with the component holder and has a hole through which a portion of the component can extend. A cover mates with the component holder. As used herein, “mates” includes the use of screws and/or other commercially suitable fasteners.
As used herein, the term “structural barrier” should be construed broadly to mean any sort of mechanical barrier used as a ceiling, wall, door, or floor. Structural barriers can be made of any suitable material, including for example, plywood, plaster, wood, wood pulp, gypsum, stone, concrete, brick, and so forth. One preferred material is Aquatough™, due to its strength and water-resistance. The structural barriers can be supporting or non-supporting, so that even acoustic tiles used in a ceiling would be considered structural barrier as the term is used herein. Similarly, wooden logs that form a wall in a log house would also be considered a structural barrier as the term is used herein. Subsets of structural barriers include ceiling/wall structural barriers (i.e., barriers used as ceilings and/or floors), and wall structural barriers (i.e., barriers used as walls).
In a preferred configuration, the structural barriers are panels, and the panels each have a hole that is skirted (i.e., at least partially surrounded) by a recess. Such recesses can advantageously be configured such that the assembled cover and spackle rim are flush with the spackled structural barrier, for example.
It is contemplated that the panels could be prefabricated with the holes and recesses to reduce the time and cost of installation. Such holes and recesses could be fabricated such that the components and covers are flush mounted with the finished wall, ceiling, floor or other surface. Flush mounting could be achieved in part using a spackle rim around the hole(s) such that the structural barrier is spackled up to the point of the spackle rim to create a uniform surface. Alternatively or additionally, the front of the components (or their corresponding covers) could have a unique prominence from the structural barrier. As defined herein, a “prominence” is a projection or a recess of a noticeable distance from the structural barrier. By way of example, contemplated prominences are a concave pattern, a convex pattern, a wavy pattern, a protruding three-dimensional logo, and a recessed engraving.
Though all commercially-suitable rear brackets are contemplated, the rear bracket preferably is a box with at least one opening such that a portion of the component could extend into the box. Preferred boxes should be approved as construction materials. The boxes could have one or more pre-punched holes to be removed as needed to feed cables and other wires into the boxes. Unless the context dictates the contrary, all ranges set forth herein should be interpreted as being inclusive of their endpoints and open-ended ranges should be interpreted to include only commercially practical values. Similarly, all lists of values should be considered as inclusive of intermediate values unless the context indicates the contrary.
The component holder is preferably coupled to the rear bracket by one or more screws, though all commercially-suitable fasteners are contemplated, including for example, nails, bolts, clamps, hooks and loops, and other mechanical fasteners, glues and other adhesives, magnets, and any combination(s) thereof. The spackle rims could have a rough surface and a hardness that allows the spackle rims to be sanded such as between 110-140 on the Rockwell R scale.
In preferred embodiments, the component holders include spackle rims that could be of any commercially suitable size and dimension. Preferred rims have a sloped configuration and a height of between 2-4 mm.
Contemplated spackle rims could have a single edge, for example in the shape of a half-circle along an edge of the component holders, two edges, for example in the shape of a triangle along an edge of the component holders, three edges, four edges, or more. Preferred spackle rims form a rectangle at the edges of the component holders, and are of uniform thickness along all of the rims' edges. The spackle rims could be either integral with the component holders or separately coupled. Such rims are advantageous as they provide a barrier that prevents spackle from being unintentionally applied to the cover, shield, or other portions of the mounting system. For example, after the structural barrier is placed within a wallboard opening in the wallboard, an installer can spread a spackle component across wallboard and the structural barrier up to the spackle rim to maintain a superficially continuous surface from the wallboard to the spackle rim.
Alternatively or additionally, the intermediate piece could include a spackle rim, such as those described above.
A spackle landing could extend laterally from the spackle rim, and preferably skirts the spackle rim. It is contemplated that the spackle landing could include one or more spackle adhering textures. The spackle adhering texture preferably has a plurality of grooves to assist adherence of the spackle to the spackle landing.
In especially preferred embodiments, the component holders advantageously include a height adapter such that a standard sized and dimensioned rear bracket and component holder can be adapted to mount differently sized and dimensioned components. Thus, for example, relatively small set of standard sized and dimensioned mounting components could be used for installation of power outlets, switches, electrical outlets, cameras, sensors, thermostats, and other components. It is contemplated that the height adapter could be integral with, or separately coupled to, the component holder. In addition, multiple height adapters could be used. The height adapters could be coupled to different pieces of the mounting system. Use of such a standard component mounting system (a) simplifies the complexity of installing the components, (b) likely reduces the cost of installing the components, and (c) allows the various installations to have a common appearance when installed.
The intermediate pieces of the mounting systems preferably have one or more holes through which the component can extend. The intermediate pieces preferably include one or more magnets to magnetically couple the cover to the intermediate piece. In this instance, and where other upper limits are not expressly stated, the reader should infer a reasonable upper limit. In this instance, for example, a commercially reasonable upper limit is about 15. It is contemplated that the intermediate piece could be formed of a ferrous material with magnets being coupled to the cover.
Preferred intermediate pieces have front sections that are recessed from front sections of the component holders. This is beneficial as it allows the cover or shield to be flush with the spackling rim of the component holder when the cover or shield is mated with the intermediate piece.
The covers (facia plates) can be sized and dimensioned to fit within recesses formed by the component holders and the intermediate pieces. Such covers could thereby fit flush with the component holder once installed. Alternatively, the front sections of the covers could be sized and dimensioned to fit slightly recessed from the tops of the spackle rims when the covers are mated with the component holders. As used herein, “slightly recessed” means a recess of no more than 4 mm from a top of the spackle rim, preferably no more than 3 mm, and more preferably no more than 2 mm. Such recess allows for the spackle rim to be lightly sanded while decreasing the chance of inadvertently sanding of the cover.
The covers could have any suitable colors, textures, finishes, patterns, shapes (e.g., rectangular, circular, ovular, triangular, etc.), prominence, and/or combinations thereof.
Preferred covers are magnetically coupled to the corresponding intermediate pieces, though all commercially-suitable fasteners are contemplated.
Contemplated mounting systems could also include a shield that is sized and dimensioned to mate with the component holder. Such shields preferably abut the spackle rims to prevent spackle, paint or other debris from entering the holes and/or damaging the components. In addition, such shield can advantageously be used to protect the component during sanding of the spackled structural barrier and/or the spackle rim. The shield could have a variety of measuring devices that assist an installer of the mounting system including for example, a bubble or laser leveler.
The laser leveler should be aimed in a variety of directions. For example, the laser leveler could shine a beam of light across the front surface of the structural barrier with a width that is substantially perpendicular to the front surface of the wallboard to ensure that the panel is positioned at an appropriate height. As used herein, “substantially perpendicular” means an angle that is within 5 degrees of 90 or 270 degrees. Alternatively, the laser leveler could shine a beam of light across the front surface of the structural barrier with a width that is substantially parallel to the front surface of the wallboard. As used herein, “substantially parallel” means an angle that is within 5 degrees of 0 or 180 degrees. Preferably, laser light from the laser leveler hits a portion of the spackle rim. A laser light that shines across a front surface of the structural barrier and hits the spackle rim would hit any lumps of spackle that extend outwardly beyond the edge of the spackle rim. An installer could then flatten or sand the surface of the spackle component until the laser light disappears. In an exemplary embodiment, the laser leveler could rotate about an axis so as to shine across any portion of the front surface of the structural barrier along a path that is substantially perpendicular to the front surface of the wallboard.
Preferred structural barriers have compositions and thicknesses that match the wallboard to which they are being finished, in terms of thickness, composition, and so forth. The structural barrier preferably has a thickness within 20%, 15%, 10%, 5%, or 1% of the wallboard thickness. Where there are differences in composition or thickness, it is preferred that the moisture absorption rate and the thermal expansion rate of the structural barrier and the wallboard differ by no more than 30%, 20%, 10% or 5% from one another to prevent cracking and fraying. Contemplated structural barrier materials include polymers, plasters, woods, fiberboards, and gypsum. Since the structural barrier will likely be anchored to a support structure using screws, nails, or similar fasteners, preferred structural barriers have a plurality of stud attachment designations, for example depressions, markings, or screw holes, that indicate potential screw or nail positions.
Various objects, features, aspects and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 is an exploded view of a mounting system for an electrical outlet.

FIG. 2 is an exploded view of a mounting system for an electrical outlet according to another embodiment.

FIG. 3 is an exploded view of a mounting system for a control panel.

FIG. 4 is an exploded view of a mounting system for a switch.

FIG. 5 is an exploded view of a mounting system for a touch screen.

FIG. 6 is an exploded view of a mounting system for two components.

FIG. 7 is a front perspective view of a mounting system for an electrical outlet with a cover.

FIG. 8 is a front perspective view of a mounting system for an electrical outlet without a cover.

FIG. 9 is a close-up view of the mounting system of FIG. 8.

FIG. 10 is front perspective view of alternate embodiment of a mounting system.

DETAILED DESCRIPTION

In FIG. 1, mounting system 100 generally includes a rear bracket 102 and a component holder 104 that supports component 106 and cooperates with rear bracket 102 to sandwich structural barrier 108. Screws 110 are used to couple the rear bracket 102 to the component holder 104, though any commercially suitable fasteners, or combination(s) thereof, could be used.
Rear bracket 102 has five walls 102A-E and an opening 134 to form an open box. However, other shapes and configurations of rear bracket 102 are also contemplated, including for example, squares, other rectangles, ovals, and circles. Rear bracket 102 is preferably sized and dimensioned to fit snugly into hole 112, but in any event are screwed, glued, clamped, or are otherwise fastened to the component holder 104. The rear brackets are preferably molded from polyethylene or other sufficiently strong and durable thermoset plastic.
Structural barrier 108 is a panel that can be used in the construction of a wall, ceiling, floor, or other surface. Though the structural barrier 108 has a rectangular shape, it is contemplated that the structural barrier could be of any commercially suitable size and dimension.
Structural barrier 108 is a piece of gypsum board, wood, plastic, or other material (or combination of materials) sufficiently strong to support a speaker or other desired component between two studs of a wall, or joists in a ceiling, or other supports. Where plywood is used as the panel material, for example, the panel might be as thin as 0.25 inches (0.635 centimeter), but would more preferably measure at least 0.5 inches (1.27 centimeters) or 0.375 inches (0.9525 centimeter). Preferred materials include wallboard, Aquatough™, Medium Density Fiberboard (MDF), High Density Fiberboard (MDF), Acrylonitrile Butadiene Styrene (ABS), and other materials that closely match various characteristics of drywall. Multiple materials could be used, for example mixed in with one another, alternating, layered on top of one another, or some combination(s) thereof. Preferably, the material has equal moisture absorption and coefficient of thermal expansion as the surrounding wallboard, while having greater durability and strength for attaching heavy components directly to the panel. For example QuietRock® 525 could be a paneling material used where the wallboard comprises drywall. It is preferable for the structural barrier 108 to have a width at least six or twelve inches greater than the spacing between studs. This extra width allows the installer considerably greater flexibility in positioning the panel on the wall.
Structural barrier 108 is typically about twenty inches (about 50 cm) to twenty-four inches (about 60 cm) in width, but it is contemplated that the panels could have any other commercially suitable dimensions, even for example, up to the dimensions to replace an entire sheet of wallboard. Narrower panels are also contemplated, although they would likely not have a sufficient width to extend between wall studs or ceiling joists. Suitable panels would usually have a width of at least six inches (15.24 cm), or more preferably, twelve inches (30.48 cm) greater than the spacing between studs, which allows the installer considerably greater flexibility in positioning the panel on the wall. While structural barrier 108 is shown as a substantially planar apparatus, structural barrier 108 could be concave, convex, or any other shape to either match the shape of the wallboard, or to introduce a non-planar surface to the wallboard.
In ordinary parlance, a wallboard is a building board made for surfacing rather than for insulating ceilings and walls. Wallboards are often made into large rigid sheets that are fastened to the frame of a building to provide a surface finish. However, as used herein, the term “wallboard” should be construed broadly to mean any sort of mechanical barrier for surfacing ceilings or walls, including doors. Wallboards could be made of any suitable material, including for example plywood, plaster, wood, wood pulp, or gypsum. As used herein, the term “wallboard” excludes floors.
The structural barrier 108 has a hole 112 that can be of any suitable size and dimension. Preferred holes are rectangular to accommodate common rectangular components, for example light switches, wall outlets, volume controls, and home security systems. However, the holes could also be ovular, circular, or any other desired shape. The area of the hole is generally dependent on the size of the component holder, and could range up to 80 in²(about 520 cm²) or larger. Especially preferred holes have an area of at least 10 in²(about 65 cm²), 20 in²(about 130 cm²), and even 30 in²(about 195 cm²). Nevertheless, for stability, it is contemplated that the structural barrier would have holes with a length that is no more than half or one third the length of the structural barrier.
Hole 112 could be positioned in any suitable arrangement relative to the structural barrier 108, and indeed FIG. 1 shows an embodiment where the hole 112 is laterally off center with respect to the structural barrier 108. The holes could be cut at a job site or elsewhere by an installer, but are more conveniently precut (or molded to include the hole) at the manufacturer. It is possible for a structural barrier to have punch-out holes or perhaps cutout lines to facilitate selection of the position of the hole at the job site, but those options are currently disfavored relative to a manufactured pre-cut or molded hole and a relatively large structural barrier.
Hole 112 extends from a front side of the structural barrier 108 to a back side of structural barrier 108. The “front side” of the structural barrier is defined herein as the side of the structural barrier that is facing outwards when the structural barrier is installed to a stud or other structural support. The front side includes any spackle that may need to be spread over the front of the panel up to the spackling rim. The “back side” of the structural barrier is defined herein as the side of the structural barrier that is directly opposite to the front side. As a hole 112 extends from a front side of the structural barrier to the back side, the hole 112 necessarily links a front side of the structural barrier 108 to the back side of the structural barrier 108 when installed.
A recess 114 projects into hole 112 and skirts the perimeter of hole 112. The recess 114 is also slightly recessed from the front side of the structural barrier 108. Recess 114 preferably extends more than 1 cm, 2 cm, or 5 cm into the hole 112 but can extend a lesser distance depending on the strength of the structural barrier 108. Recess 114 is also preferably recessed by about 1 cm from the front side of the structural barrier 108, allowing ample room for the component holder 104 to be situated within the hole 112. Here, recess 114 includes indentations 116 such that the recess 114 is sized and dimensioned to fit the size and dimension of the component holder 104. It is contemplated that such indentations could be varied or even eliminated depending on the configuration of the component holder 104.
Component holder 104 is disposed within a hole 112 in structural barrier 108, and mates with the rear bracket 102. The component holder 104 includes height adapters 118 that provide an adjustable mount to enable a variety of components to mate with component holder 104. Height adapters could be removable from or permanently coupled to the component holder 104. In addition, the height adapters 118 could be adjustable in length, height, and/or depth. Though the component holder 104 preferably has two height adapters 118, any commercially suitable number of height adapters could be used.
Component holder 104 also comprises a spackle rim 136 and a spackle landing 138 that skirts an outer circumference of the spackle rim 136. Though the spackle rim 136 and spackle landing 138 are shown as integral to the component holder 104, one or both of the spackle rim 136 and spackle landing 138 could separately coupled to the component holder 104.
The spackle rim 136 has a sloped configuration, though any commercially-suitable configuration is contemplated. Preferably, the spackle rim has a height of between 2-4 mm, though any commercially suitable height is contemplated. The spackle rim 136 has a rough surface but preferably has a hardness such that the rim 136 can be sanded.
As shown in the figures, the spackle rim 136 preferably comprises a spackle landing 138 is sized and dimensioned to extend outwardly from the spackle rim 136 by a very small distance, and preferably less than 0.125 inches, and more preferably about 1/16 inch (about 1-3 mm).
Though component 106 is shown as an electrical outlet that mates with height adapters 118, though it is contemplated that the component 106 could mate with component holder 104 directly. Screws 120 are used to secure component 106 to the height adapters 118. However, any commercially suitable fasteners could be used. In addition, the number of fasteners could be varied as needed to properly mate component 106.
As used herein, “component” should be interpreted as generically representing all practical wall mounted components, including for example, electrical outlets, data connectors, controllers, light and other switches, lighting, sprinkler systems, smoke detectors, speakers, touch screens, and so forth. The various electrical and data wires and other cables are not shown in the figures, but should be assumed, and could be those conventionally contemplated in the art.
Mounting system 100 further includes an intermediate piece 122 that mates with the component holder 104 and includes a hole 124 through which a portion of component 106 can extend. Preferred intermediate pieces include one or more magnets 126 configured to magnetically couple cover 130 to intermediate piece 122. Screws 128 or other commercially suitable fasteners are used to couple intermediate piece 122 to component holder 104.
Cover 130 can be mated with the component holder 104 and held in place by magnets 126. Cover 130 preferably covers at least a portion of component 106. Cover 130 can optionally include indicia 132 or other designs. In this case, the indicium is the Trufig™ trademark, which comprises a square with a capitalized T within the square. While cover 130 is shown as a substantially rectangular plate, the cover could be of any commercially suitable size and dimension.
FIG. 2 illustrates an alternative embodiment of a mounting system 200 that comprises shield 240 that can be mated with component holder 204. Shield 240 preferably covers component 206 and the intermediate piece 222, but could alternatively cover hole 212, such as when the component has not yet been installed. Shield 240 thereby prevents mud, drywall, paint, or other material from entering the interior of the hole 212. Shield 240 could be removed after spackling. The shield 240 is particularly helpful for when an electronic component is preinstalled prior to spackling, as the shield 240 prevents a substantial amount of foreign particular from adulterating the electronic component. With respect to the remaining numerals in FIG. 2, the same considerations for like components with like numerals of FIG. 1 apply.
In FIG. 3, another embodiment of a mounting system 300 includes a rear bracket 302 and a component holder 304 that supports controller 306. The component holder 304 cooperates with rear bracket 302 to sandwich structural barrier 308. With respect to the remaining numerals in FIG. 3, the same considerations for like components with like numerals of FIG. 1 apply.
FIG. 4 illustrates yet another embodiment of a mounting system 400 that includes a rear bracket 402 and a component holder 404 that supports switch 406. The component holder 404 cooperates with rear bracket 402 to sandwich structural barrier 408. With respect to the remaining numerals in FIG. 4, the same considerations for like components with like numerals of FIG. 1 apply.
FIG. 5 illustrates a mounting system 500 having a rear bracket 502 that mates with a component holder 504 and thereby sandwiches structural barrier 508. The rear bracket 502 is a rim configured to hold the component holder 504 to the structural barrier 508 and thereby secure the component holder 504 in place.
The component holder 504 is inserted within hole 512 of the structural barrier 508, and rests on recess 514 that skirts the outer circumference of hole 512.
Component 506 is a touch screen that is positioned through the component holder 504 and hole 512. Component 506 includes an intermediate piece 522 that mates with the component holder 504 to secure the intermediate piece 522 to the component holder 504. A top bracket 554 and a bottom bracket 556 are used to secure the component 506 in place once installed. The intermediate piece 522 includes a plurality of magnets 526 to secure cover 530 to the intermediate piece 522. Cover 530 can include indicia 532 such as for advertisement or decorative purposes, for example. With respect to the remaining numerals in FIG. 5, the same considerations for like components with like numerals of FIG. 1 apply.
FIG. 6 shows how the structural barrier 108 of FIG. 1 can have multiple holes. Hole 112 of FIG. 1 is replaced by first and second holes 612-613. All the features and inventive concepts of FIG. 1 can be incorporated into a structural battier with multiple holes. In addition, while the structural barrier 608 is shown with two holes, the number of holes can be varied. Likewise, the alignment, size, shape, and orientation of the holes can also be varied.
First and second rear brackets 602-603 are mated with first and second component holders 604-605, respectively, and thereby each mated pair thereby sandwiches structural barrier 608. First and second component holders 604-605 support respective first and second components 606-607. Though first component 604 is an electrical outlet and second component 605 is a data interface, it is contemplated that the components could be the same, such as two electrical outlets. Alternatively, any commercially suitable components could be substituted for one or both of the first and second components.
Preferably first and second recesses 614-615 skirt the perimeters of respective first and second holes 612-613. Each of the recesses 614-615 can have first and second indentations 616-617, respectively, such that the recesses 614-615 are sized and dimensioned to fit with component holders 604-605.
The component holders 604-605 can include respective first and second height adapters 618-619. A non-adjustable mount could be substituted for one or more of the height adaptors 618-619. Components 606-607 each mates with respective component holders 604-605. Screws 620-621 are used to secure components 606-607 to the component holders 604-605, though any commercially suitable fasteners could be used.
Mounting system 600 also includes first and second intermediate pieces 622-623 that each mate with respective first and second component holder 604-605, and each of the first and second intermediate pieces 622-623 includes a hole 624-625 through which a portion of components 606-607 can extend. Preferred intermediate pieces include magnets 626-627 configured to magnetically couple first and second covers 630-631 to first and second intermediate pieces 622-623, respectively. Screws 628-629 or other commercially suitable fasteners are used to couple intermediate pieces 622-623 to component holders 604-605. The covers 630-631 can be mated with component holders 604-605 and held in place by magnets 626-627.
FIG. 7 illustrates an assembled mounting system 700. Component holder 704 cooperates with a rear bracket (not shown) to sandwich structural barrier 708. The component holder 704 includes a spackle rim 736 and a spackle landing 738.
Cover 730 includes apertures 742A-C that are each sized and dimensioned to match corresponding female connectors of a standard U.S. electrical outlet (not shown). However, the apertures would likely be varied in size, dimension, and number as needed to match the connector configuration of the component. It should be appreciated that an electrical outlet is used euphemistically to represent any mounted component in the category of power and data interfaces, including for example, Ethernet ports, A/V jacks, telephone jacks, and fiber optic jacks. Thus, for example, a cover for a coaxial cable outlet might have a single circular aperture sized and dimensioned such that the coaxial cable connector could extend through the aperture of the cover. A front section 748 of the cover 730 is slightly recessed from a top 750 of the spackle rim 736.
In FIG. 8, assembled mounting system 800 is shown without a cover. Component holder 804 cooperates with a rear bracket (not shown) to sandwich structural barrier 808. The component holder 804 includes a spackle rim 836 and a spackle landing 838 that extends laterally from the spackle rim 836. The component holder 804 supports electrical outlet 806. An intermediate piece 822 mates with component holder 804 and is secured by screws 828. Four magnets 826 are used to magnetically couple a cover (not shown) to the intermediate piece 822; however, the precise number of magnets could be varied. In addition, any commercially suitable fastener could be used. As can be seen, a front section 844 of the intermediate piece 822 is recessed from a front section 846 of the component holder 804, such that the cover (not shown) will fit within the recess formed by the intermediate piece 822 and the component holder 804.
In FIG. 9, an assembled mounting system 900 is shown without a cover. The component holder 904 includes a spackle rim 936 and a spackle landing 938 that extends laterally from the spackle rim 936. The spackle landing includes a spackle adhering texture 951 that comprises a plurality of grooves 952. It is contemplated that the number of grooves, their orientation, their size, and/or their dimension could be varied. It is also contemplated that the spackle adhering texture 951 could comprise a plurality of grooves of various sizes and dimensions. With respect to the remaining numerals in FIG. 9, the same considerations for like components with like numerals of FIG. 8 apply.
In FIG. 10, intermediate piece 1022 is shown having a spackle rim 1058. With respect to the remaining numerals in FIG. 10, the same considerations for like components with like numerals of FIG. 8 apply.
It should be apparent to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims. Moreover, in interpreting both the specification and the claims, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced. Where the specification claims refers to at least one of something selected from the group consisting of A, B, C . . . and N, the text should be interpreted as requiring only one element from the group, not A plus N, or B plus N, etc.

Claims

1. A mounting system for installing a component in a structural barrier, comprising:

a rear bracket;

a component holder that supports the component, and cooperates with the rear bracket to sandwich the structural barrier;

an intermediate piece that mates with the component holder and includes a hole through which a portion of the component can extend; and

a cover that mates with the component holder.

2. The mounting system of claim 1, wherein the rear bracket comprises a box with at least one opening.

3. The mounting system of claim 2, wherein the component holder is coupled to the box by a screw.

4. The mounting system of claim 1, wherein the component holder has a spackle rim.

5. The mounting system of claim 1, wherein the component holder has a height adapter.

6. The mounting system of claim 1, wherein the structural barrier is a panel having a hole that is skirted by a recess.

7. The mounting system of claim 1, wherein a front section of the intermediate piece is recessed from a front section of the component holder.

8. The mounting system of claim 1, wherein the cover is sized and dimensioned such that the cover fits within a recess formed by the component holder and the intermediate piece.

9. The mounting system of claim 4, wherein a front section of the cover is sized and dimensioned such that the front section is slightly recessed from a top of the spackle rim when the cover is mated with the component holder.

10. The mounting system of claim 1, wherein the intermediate piece has a spackle rim.

11. The mounting system of claim 10, wherein the spackle rim has a rough surface.

12. The mounting system of claim 4, wherein the component holder has a spackle landing with a spackle adhering texture that extends laterally from the spackle rim.

13. The mounting system of claim 1, further comprising a shield that is sized and dimensioned to mate with the component holder.