U.S. patent application number 13/366674 was filed with the patent office on 2012-05-31 for connection box assembly method.
This patent application is currently assigned to CHEETAH USA CORP.. Invention is credited to Brent L. Kidman.
Application Number | 20120132456 13/366674 |
Document ID | / |
Family ID | 30771524 |
Filed Date | 2012-05-31 |
United States Patent
Application |
20120132456 |
Kind Code |
A1 |
Kidman; Brent L. |
May 31, 2012 |
CONNECTION BOX ASSEMBLY METHOD
Abstract
A method for assembling an electrical connection box. The method
may include the steps of selecting a connection box having at least
one receiver, selecting an assembly comprising an electrical
fixture and at least one anchor, and securing the assembly to the
connection box by inserting the at least one anchor within the
first receiver. The at least one receiver may include a first
engagement mechanism designed to engage a second engagement
mechanism included as part of the at least one anchor.
Inventors: |
Kidman; Brent L.; (Spanish
Fork, UT) |
Assignee: |
CHEETAH USA CORP.
|
Family ID: |
30771524 |
Appl. No.: |
13/366674 |
Filed: |
February 6, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12727091 |
Mar 18, 2010 |
8109785 |
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13366674 |
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11286033 |
Nov 23, 2005 |
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12727091 |
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10435716 |
May 8, 2003 |
7118413 |
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11286033 |
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09974306 |
Oct 10, 2001 |
6609927 |
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10435716 |
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60273803 |
Mar 6, 2001 |
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60297823 |
Jun 12, 2001 |
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Current U.S.
Class: |
174/54 ;
174/66 |
Current CPC
Class: |
Y10T 29/49147 20150115;
Y10T 29/49117 20150115; H02G 3/086 20130101; H01R 13/73 20130101;
Y10T 29/49174 20150115; Y10T 29/49208 20150115; H01R 13/506
20130101; H02G 3/18 20130101; H01R 25/006 20130101; H02G 3/14
20130101 |
Class at
Publication: |
174/54 ;
174/66 |
International
Class: |
H01H 9/02 20060101
H01H009/02; H02G 3/14 20060101 H02G003/14 |
Claims
1-20. (canceled)
21. A fixture configured to be secured to a connection box and be
at least partially covered by a face plate, the fixture comprising:
a main body; and at least one flange extending from the main body,
the at least one flange defining a fixture securement aperture
configured to receive a fastener for securing the fixture to the
connection box and defining at least one face plate engagement
aperture configured to receive a prong extending from the face
plate in a manner that secures the face plate to the fixture.
22. The fixture of claim 21 wherein the fixture is a power
receptacle and the main body includes a first electrical socket and
a second electrical socket.
23. The fixture of claim 21 wherein the at least one flange
comprises a first flange extending from a first end of the main
body and a second flange extending from an opposite second end of
the main body.
24. The fixture of claim 21 wherein the at least one flange
comprises at least one extension configured to extend beyond an
outer periphery of the connection box and hold the fixture flush
with a wall to which the connection box is mounted.
25. The fixture of claim 21 wherein the at least one face plate
engagement aperture comprises a first face plate engagement
aperture and a second face plate engagement aperture.
26. The fixture of claim 25 wherein the first face plate engagement
aperture and the second face plate engagement aperture are circular
in shape.
27. The fixture of claim 25 wherein the fixture securement aperture
is located between the first face plate engagement aperture and a
second face plate engagement aperture.
28. A face plate configured to at least partially cover a fixture
having a flange used for securing the fixture to a connection box,
the face plate comprising: a body having a front face and an
opposite rear face; and at least one prong outwardly extending from
the rear face of the body, the at least one prong configured to be
inserted into an aperture in the flange of the fixture to secure
the face plate to the fixture.
29. The face plate of claim 28 wherein at least a portion of the at
least one prong is configured to reduce in diameter while passing
through the aperture in the flange of the fixture and to increase
in diameter after passing through the aperture to secure the face
plate to the fixture.
30. The face plate of claim 28 wherein the at least one prong is
configured to engage substantially the entirety of a perimeter of
the aperture in the flange of the fixture to secure the face plate
to the fixture.
31. The face plate of claim 28 wherein the at least one prong is
configured to extend from the rear face of the body such that it is
not visible from the front face of the body after the face plate is
secured to the fixture.
32. The face plate of claim 28 wherein the at least one prong
comprises at least one hook configured to engage an edge of the
aperture after the prong is inserted to at least partially resist a
removal force.
33. The face plate of claim 32 wherein the at least one hook
includes an inside taper that allows the at least one hook to flex
inward when a predetermined removal force is applied so that the
face plate can be selectively removed from the fixture without
damaging the at least one prong.
34. The face plate of claim 32 wherein the at least one hook is
secured to the face plate by a flexible neck that allows at least
one hook to deflect inward when being inserted into the
aperture.
35. The face plate of claim 34 wherein the at least one hook
comprises a plurality of hooks, each hook being secured to the face
plate by a separate flexible neck.
36. The face plate of claim 34 including a gap between the
plurality of hooks configured to provide clearance that allows the
plurality of hooks to flex inward when the at least one prong is
inserted into the aperture.
37. The face plate of claim 28 wherein the at least one prong
comprises a first prong for engaging a first flange of the fixture
and a second prong for engaging a second flange of the fixture.
38. A device configured to be secured to a connection box, the
device comprising: a fixture including a main body and at least one
flange extending from the main body, the at least one flange being
used to secure the device to the connection box; and a face plate
configured to be secured to the fixture, the face plate including
at least one prong that is configured to be inserted into a face
plate engagement aperture defined by the at least one flange to
secure the face plate to the fixture, wherein the at least one
prong is not visible from a front side of the face plate.
39. The device of claim 38 wherein the at least one flange further
defines a fixture securement aperture configured to receive a
fastener for securing the fixture to the connection box.
40. The device of claim 38 wherein the fixture is a power
receptacle and main body includes a first electrical socket and a
second electrical socket.
Description
RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 10/435,716 filed May 8, 2003 and entitled
QUICK ASSEMBLING ELECTRICAL CONNECTION BOX APPARATUS AND METHOD,
which is a continuation of U.S. Pat. No. 6,609,927 issued Aug. 26,
2003, which claims the benefit of U.S. Provisional Patent
Application Ser. No. 60/297,823 filed Jun. 12, 2001 and U.S.
Provisional Patent Application Ser. No. 60/273,803 filed on Mar. 6,
2001.
BACKGROUND
[0002] 1. The Field of the Invention
[0003] This invention relates to fixture anchoring and, more
particularly, to novel systems and methods for facilitating
connection box assembly.
[0004] 2. The Background Art
[0005] Manually installing screws or other fasteners is often time
consuming. Additionally, in certain installations, the installer
must employ his or her hands to hold several components as well as
rotate a tool transferring rotation to a screw or other type of
fastener. Maintaining all of the components in proper alignment is
often difficult and requires skill. In any case, the complexity
slows the installation process.
[0006] Power tools may simplify the installation process by
providing the motion (e.g. rotation) necessary to advance or
install a fastener. The power tool must, however, be held and
positioned in a manner similar to a manual tool. Thus, the use of
power tools may not significantly lessen the demands on the
installer.
[0007] An electrical connection box assembly is one example of a
time consuming fastener installation. Once an electrical fixture
has been wired, the fixture is typically secured inside a
connection box. Securement of the electrical fixture to the
connection box often involves the installation of multiple screws.
These screws are generally over an inch long and are relatively
finely threaded. The length of the screws may be selected to
accommodate various connection box placements and wall paneling
thicknesses. To complete a conventional electrical connection box
assembly, a face plate is secured to the fixture by another screw.
Similar problems may be encountered in the installation of
connections boxes used for a wide variety of devices and systems,
including without limitation telephone, stereo, computer network,
information systems, cable television system, and security systems
fixtures.
[0008] The installation of the connection box screws requires an
installer concurrently to hold a fixture, maintain screw alignment,
and provide rotation to the screw. Often it is difficult to
initiate engagement between the screw and the receiving hole. Such
difficulty typically arises because the receiving hole may be
obscured by the wall paneling or recessed into the wall. Once the
screw is in engagement with the receiving hole, the time consuming
and often laborious task of advancing the finely threaded screw
remains.
[0009] Face plate screws and other securement devices may be
unsightly as well as time consuming and laborious to install.
Screws used to secure face plates to connection boxes and fixtures
are typically painted and are, therefore, exposed to chipping,
tarnishing, wear, and oxidation. In certain applications, it may be
desirable to use a snap-on face plate to provide fast securement
without the use of screws to provide securement.
[0010] Fixture installation may consume a large portion of an
electrician's time budget for any given project. If the amount of
time needed to install electrical fixtures were reduced, both the
installer and the financier (e.g. home owner, developer, or the
like) may realize large economic rewards.
[0011] Attempts have been made to provide quick assembling
connection boxes and fixture assemblies. Quick assembling devices
typically involve at least some rotation of the fixture screws and,
therefore, require the use of tools for installation. Often these
devices are limited in how well they are able to engage the threads
of the fixture screws. Thus, such devices may not provide a
reliable and solid securement between the fixture and connection
box.
[0012] Typical screwless face plates require additional components
to enable securement to the electrical fixture. These additional
components increase manufacturing cost as well as installation
time.
[0013] What is needed is an anchor that provides a strong and
reliable securement between a fixture and associated connection
box. Such an anchor would also provide for quick and simple
installation thereof. Additionally, a screwless face plate that
requires no additional components to accomplish a reliable
securement would be an advancement in the art. Such a connection
box assembly would greatly reduce the time, skill level, and effort
required to assemble and complete connection box installation (e.g.
electrical fixture installation or the like).
BRIEF SUMMARY AND OBJECTS OF THE INVENTION
[0014] In view of the foregoing, it is a primary object of the
present invention to provide an apparatus and method requiring
minimal time, effort, and skill to install.
[0015] It is a further object of the invention to provide a
connection box apparatus and method that may be installed without
screw rotation.
[0016] Consistent with the foregoing objects, and in accordance
with the invention as embodied and broadly described herein, a
method and apparatus are disclosed. An embodiment in accordance
with the present invention may provide an apparatus for securing a
fixture to a connection box. In a factory manufacturing process an
anchor may be secured to a fixture. In one embodiment, the anchor
is secured to the fixture by a releasable fastener. The anchor may
have an engagement mechanism formed therewith.
[0017] A connection box may be provided to house lines or wires
originiating from a signal source to terminate therein. The lines
may provide a connection for the fixture. A receiver may be
associated with the connection box. The receiver may have an
engagement mechanism formed to receive and retain the engagement
mechanism of the anchor. Thus, the anchor and receiver may be
intermediaries in the securement of the fixture to the connection
box.
[0018] In certain applications, screws and other securement devices
may be unsightly. In these applications it may be desirable to
provide a snap-on face plate to provide fast securement without the
use of screws. Face plates are often secured to fixtures to cover
and hide the wiring and access holes therebehind. Face plates in
accordance with the present invention may have engagement prongs.
These prongs may be inserted through apertures in a corresponding
fixture to maintain the face plate aligned securely
thereagainst.
[0019] In selected embodiments in accordance with the present
invention, an installer may first connect a fixture to the lines or
wires housed in a connection box. A face plate may be installed by
simply pressing the engagement prongs through the appropriate
apertures in the fixture. Once a fixture has been connected to the
lines and a face plate applied, the fixture may be secured to the
connection box by inserting one or more of the attached anchors
into corresponding receivers associated with the connection box.
The anchors may be inserted a selected distance into the receivers
until the face plate is properly positioned. Insertion of an anchor
into a receiver may be accomplished without the aid of tools.
[0020] The method of engagement between the engagement mechanism of
the receiver and that of the anchor may be selected to provide a
fast, clean securement. In selected embodiments, the engagement
mechanism of the receiver may be a barb configured to engage a
series of teeth provided as part of the engagement mechanism of the
anchor. In other embodiments, the engagement mechanism of the
anchor may be a barb configured to engage a series of teeth
provided as part of the engagement mechanism of the receiver. The
engagement between the anchor and receiver may provide a single or
multiple locking positions.
[0021] By applying embodiments in accordance with the present
invention, a fixture may be secured to a connection box in a
comparatively short amount of time. Embodiments in accordance with
the present invention may be particularly advantageous when it is
desirable to preserve the ability to remove the fixture from the
connection box. For example, an electrician or computer network
technician may need to remove a fixture to gain access to the lines
or wiring tucked therebehind. In such a situation, the face plate
may be "popped" off and the fasteners holding the fixture to the
anchors may be released, thus freeing the fixture. Each anchor may
maintain engagement with its corresponding receiver. After the
revisions are complete the fixture may once again be secured to the
anchors by the installation of the fastener previously
released.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The foregoing and other objects and features of the present
invention will become more fully apparent from the following
description, taken in conjunction with the accompanying drawings.
Understanding that these drawings depict only typical embodiments
of the invention and are, therefore, not to be considered limiting
of its scope, the invention will be described with additional
specificity and detail through use of the accompanying drawings in
which:
[0023] FIG. 1 is an exploded perspective view of a connection box
assembly in accordance with the present invention;
[0024] FIG. 2 is a perspective view of one embodiment of an anchor
in accordance with the present invention;
[0025] FIG. 3 is a perspective view of an alternative embodiment of
an anchor in accordance with the present invention;
[0026] FIG. 4 is a perspective view of another alternative
embodiment of an anchor in accordance with the present
invention;
[0027] FIG. 5 is a top cross-sectional view of an engagement
between an anchor and receiver in accordance with the present
invention;
[0028] FIG. 6 is a front cross-sectional view of the engagement of
FIG. 5;
[0029] FIG. 7 is a partial perspective view of an alternative
embodiment of an anchor in accordance with the present
invention;
[0030] FIG. 8 is a top cross-sectional view of an alternative
engagement between an anchor and receiver in accordance with the
present invention;
[0031] FIG. 9 is a top cross-sectional view of another alternative
engagement between an anchor and receiver in accordance with the
present invention;
[0032] FIG. 10 is a partial cutaway, perspective view of an
application of a quick assembling connection box in accordance with
the present invention;
[0033] FIG. 11 is a perspective view of a receiver in accordance
with the present invention formed as part of a metal connection
box;
[0034] FIG. 12 is an exploded perspective view of an alternative
embodiment of a face plate and fixture assembly in accordance with
the present invention;
[0035] FIG. 13 is a perspective view of a complete assembly
prepared for installation in accordance with the present
invention;
[0036] FIG. 14 is a partial perspective view of a face plate and
fixture assembly in accordance with the present invention;
[0037] FIG. 15 is a side cross-sectional view of a screwless face
plate assembly using an adapter in accordance with the present
invention;
[0038] FIG. 16 is a side cross-sectional view of an engagement
prong in accordance with the present invention;
[0039] FIG. 17 is a perspective view of an engagement prong in
accordance with the present invention;
[0040] FIG. 18 is a perspective view of a fixture with a flange
modified in accordance with the present invention;
[0041] FIG. 19 is a perspective view of an alternative embodiment
of a screwless face plate in accordance with the present invention
to engage the fixture of FIG. 18;
[0042] FIG. 20 is a side cross-sectional view of an engagement
between the fixture of FIG. 18 and the screwless face plate of FIG.
19;
[0043] FIG. 21 is a partial perspective view of alternative
engagement between a screwless face plate and an fixture in
accordance with the present invention;
[0044] FIG. 22 is a cutaway, partial perspective view of
alternative engagement between a screwless face plate and a fixture
in accordance with the present invention;
[0045] FIG. 23 is a perspective view of a fixture with an adapter
in accordance with the present invention; and
[0046] FIG. 24 is a side cross-sectional view of a fixture with an
adapter in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0047] It will be readily understood that the connection box
assemblies of the present invention, as generally described and
illustrated in the Figures herein, could be arranged and designed
in a wide variety of different configurations. Thus, the
description herein is not intended to limit the scope of the
invention, but is merely representative of certain presently
preferred embodiments of devices and systems in accordance with the
invention. Those of ordinary skill in the art will, of course,
appreciate that various modifications to the details herein may
easily be made without departing from the essential characteristics
of the invention, as described. Thus, the following information is
intended only by way of example, and simply illustrates certain
presently preferred embodiments consistent with the invention.
[0048] Referring to FIG. 1, in discussing the Figures, it may be
advantageous to establish a reliable coordinate system to aid in
the description of several of the embodiments in accordance with
the present invention. Coordinate axes 11 may be defined by
longitudinal 11a, lateral 11b, and transverse directions 11c
substantially orthogonal to one another.
[0049] A connection box assembly 10 in accordance with the present
invention may provide an apparatus for securing a fixture 12 to a
connection box 14. In a factory manufacturing process, an anchor 16
may be secured to the fixture 12. The connection box 14 to which
the fixture 12 is to be secured may have a receiver 18 associated
therewith for admitting and retaining the anchor 16. Thus, the
anchor 16 and receiver 18 may be intermediaries in the securement
of the fixture 12 to the connection box 14. A face plate 20 may be
provided to cover and hide the wiring and access holes
therebehind.
[0050] A fixture 12 may be any suitable piece for which securement
is desired. For example, a fixture 12 may be a power receptacle,
power switch, light fixture, telephone jack, network jack, cable
connector, stereo system connector, information system connector,
or any other unit 12 for which permanent or removable securement to
a connection box 14 may be desired. In a similar manner, the
connection box 14 may be any box to which a fixture 12 may be
secured. A connection box 14 may be constructed of any suitable
material. Suitable materials may include without limitation metals,
polymers, composites, and the like. Additionally, a connection box
14, in accordance with the present invention, may be of any
suitable size. For example, a connection box 14 may be a single
gang, double gang, triple gang, quadruple gang, quintuple gang, or
the like. The concepts presented herein are illustrated as a single
gang box, however, the principles and concepts may easily be
expanded to multiple-gang connection boxes.
[0051] Embodiments, in accordance with the present invention may be
particularly well suited to assemblies that may be assembled in the
field (i.e. not in a factory). Such field assemblies need not be
limited to connection box assemblies 10. Embodiments in accordance
with the present invention may provide convenience and ease of
assembly in the field where less than perfect conditions are often
encountered.
[0052] An anchor 16 in accordance with the present invention may be
constructed, formed, machined, extruded, molded, cast, or otherwise
made from any suitable material. Suitable materials may include
without limitation metals, polymers, composites, or the like. For
example, in certain embodiments, an anchor 16 may be formed of a
polymer in a molding process.
[0053] An anchor 16 may be secured to a fixture 12 in any suitable
manner. In certain embodiments, an anchor 16 may be secured to a
fixture 12 by a fastener 22 such as a bolt, rivet, screw,
engagement prong, engagement hook, or the like. In other
embodiments, an anchor 16 may be glued or otherwise bonded to a
fixture 12. Additionally, an anchor 16 may be formed as an integral
part of the fixture 12.
[0054] Each form of attachment between the anchor 16 and the
fixture 12 may have particular advantages. In certain applications,
such as the installation of power receptacles 12, switches 12,
computer network outlets 12, cable television outlets 12, and the
like an installer may need to remove a fixture 12 to gain access to
something (e.g. wiring) tucked therebehind. In such a situation,
screws 22 may provide an ideal attachment between the anchor 16 and
the fixture 12. The screws 22 may be removed, thus freeing the
fixture 12. The anchors 16 may maintain engagement with the
connection box 14. After the revisions are complete the fixture 12
may once again be secured to the anchors 16 by the insertion of the
screws 22 previously removed.
[0055] In selected applications, multiple points of securement
between a fixture 12 and a connection box 14 may exist. In such
situations, an anchor 16 in accordance with the present invention
may be applied to all or a subset of the securement locations. For
example, power receptacles 12 and switches 12 are typically secured
to connection boxes 14 by two screws spaced from each other in a
longitudinal direction 11a. An anchor 16a, 16b may be applied to
fasteners 22a, 22b respectively. Similarly, a connection box 14 may
have multiple receivers 18a, 18b to engage both anchors 16a, 16b,
respectively.
[0056] The method of engagement between a receiver 18 and an anchor
14 may be selected to provide a fast, clean securement. By so
doing, the fixture 12 may be secured to the connection box 14 in a
minimum amount of time. For example, installers (e.g. electricians,
network technicians, cable television installers, and the like)
spend a large portion of their installation time screwing fixtures
12 to connection boxes 14. In certain embodiments in accordance
with the present invention, a fastener 22 (e.g. screw 22) may be
introduced to secure an anchor 16 to the appropriate locations on a
fixture 12 by a manufacturing machine. Thus, the installation of
the fastener 22 may be performed in ideal conditions with proper
alignment and fast tool speeds. In the field, when an installer
installs the fixture 12, the time consuming screw installation no
longer needs to be performed. An anchor 16 may simply be inserted
into a receiver 18.
[0057] The embodiments of the fixture 12, connection box 14,
anchors 16a, 16b, receivers 18a, 18b, and face plate 20, as
illustrated in FIG. 1 may be arranged and designed in a wide
variety of different configurations that fall within the scope of
the present invention. Thus, the description hereinabove is not
intended to limit the scope of the possible embodiments, but is
merely representative of certain presently preferred embodiments of
devices and systems in accordance with the invention. The
information is intended only by way of example.
[0058] Referring to FIG. 2, an anchor 16 in accordance with the
present invention may have an engagement mechanism 24 configured to
provide a mechanical grip with a receiver 18. If an anchor 16 is to
be secured to a fixture 12 by a bolt 22 or screw 22, a threaded
aperture 26 may be formed therein. The threaded aperture 26 may
extend completely or only partially through the anchor 16 in a
transverse direction 11c.
[0059] A length 28 of the engagement mechanism 24 may be selected
to provide a desired number of engagement locations 30. In selected
embodiments, each engagement location 30 is a tooth 30.
Additionally, the engagement length 28 and the number of engagement
locations 30 may be selected to permit insertion of the anchor 16 a
desired distance into the receiver 18. Thus, providing a desired
alignment of the fixture 12 with respect to the connection box
14.
[0060] In selected embodiments, an anchor 14 in accordance with the
present invention may include a spacer 32. The length 34 of the
spacer 32 may be selected to provide additional control over the
spacing of the fixture 12 in relation to the connection box 14.
[0061] In certain embodiments, one end 36 of the anchor 16 may be
formed to promote easy insertion into the receiver 18. For example,
an end 36 may be pointed, rounded, tapered, or otherwise
formed.
[0062] An anchor 16 in accordance with the present invention may
have any suitable cross-section. For example, the cross-section may
be rectangular, circular, triangular, oval, an unconventional
shape, or the like. The cross-sectional shape of an anchor 16 may
be selected to resist rotation about a transverse axis 11c once
installed inside a receiver 18. For example, an anchor 16 having a
generally circular cross-section may have a key-way formed therein
to correspond to a key formed or located in the receiver 18.
[0063] The shape and configuration of a receiver 18 may be selected
to match and complement the particular shape of a selected anchor
16. For example, if an anchor 16 having a rectangular cross section
is desired, the receiver 18 may be formed to have a generally
rectangular shape. Thus, the receiver 18 may admit the anchor 16
and hold the anchor 16 securely without motion (e.g rotation about
a transverse axis 11c) therebetween.
[0064] Referring to FIG. 3, in certain embodiments, an anchor 16
may have multiple sliding surfaces 38 to promote ease of insertion
and proper alignment. A recessed groove 40 may be formed in one or
more surfaces 38 of the anchor 16 to provide a location for
disposition of an engagement mechanism 24. Such an engagement
mechanism 24 may be recessed to reduce the risk of interfering with
proper insertion of the anchor 16 into the receiver 18.
[0065] Referring to FIG. 4, an anchor 16 may have a generally
circular cross-section. In such an embodiment, the anchor may
include a single flat 42 or may include a plurality of flats 42
that provide a location for disposition of an engagement mechanism
24. The flats 42 may also provide a location for a corresponding
receiver 18 to engage the anchor 16 to resist rotation about a
transverse axis 11c.
[0066] FIG. 4 also illustrates an alternative embodiment of a
fastener 22 in accordance with the present invention. Opposing
engagement hooks 22 may be shaped to promote insertion into a
corresponding aperture in a fixture 12. The engagement hooks 22 may
be formed to engage an aperture of any suitable shape (e.g.
circular, oval, triangular, or the like). The illustrated
engagement hooks 22 have been formed in a shape to fit a square
aperture. A square aperture may provide a mechanism to resist
rotation of the anchor 16 about a transverse axis 11c with respect
to a corresponding fixture 12. Engagement hooks 22 in accordance
with the present invention may flex to allow an anchor 16 to be
separated from the fixture 12 to which the anchor 16 is attached.
Once separated, the anchor 16 and fixture 12 may be reattached by
reinserting the engagement hooks 22 of the anchor 16 through the
corresponding aperture in the fixture 12.
[0067] The embodiments of anchors 16, as illustrated in FIGS. 2-4
could be arranged and designed in a wide variety of different
configurations that fall within the scope of the present invention.
Thus, the description hereinabove is not intended to limit the
scope of the possible embodiments, but is merely representative of
certain presently preferred embodiments of devices and systems in
accordance with the invention. The information is intended only by
way of example and not by way of limitation.
[0068] Referring to FIGS. 5-6 while continuing to refer generally
to FIGS. 1-4, as discussed hereinabove, an anchor 16 in accordance
with the present invention may have multiple sliding surfaces 38.
The sliding surfaces 38 may maintain proper alignment of the anchor
16 with respect to the receiver 18.
[0069] In selected embodiments, a receiver 18 in accordance with
the present invention may include an engagement mechanism 39. This
engagement mechanism 39 may be configured to engage the engagement
mechanism 24 of an anchor 16. In selected embodiments, an
engagement mechanism 39 may comprise hooks 44 or barbs 44. These
barbs 44 may extend from the receiver 18 with a shape selected to
engage the teeth 30 of the anchor 16. The engagement of the hooks
44 and teeth 30 may be selected to provide unidirectional motion so
that an anchor 16 may be easily inserted yet resist removal in a
transverse direction 11c. The number of teeth 30 and the
incremental distance 46 therebetween may be selected to provide a
continuum of possible locking positions between the anchor 16 and
the receiver 18.
[0070] Referring to FIGS. 7-8 while continuing to refer generally
to FIGS. 1-6, in an alternative embodiment, an anchor 16 may
include a single hook 44. In selected embodiments, an anchor 16 may
include multiple hooks 44. A flexible region 48 may permit a hook
44 to flex as it "clicks" or passes over the teeth 30 of a receiver
18. As discussed hereinabove and as best shown in FIG. 8, the
number of teeth 30 and the incremental distance 46 therebetween may
be selected to provide a continuum of possible locking positions
between the anchor 16 and the receiver 18.
[0071] Referring to FIG. 9, in selected embodiments, the engagement
between an anchor 16 and a receiver 18 may not be incremental,
rather a single locking position may be defined. In such an
embodiment, the anchor 16 may be inserted into the receiver 18
until a lock 50 is activated. In selected embodiments, a lock 50
may consist of a hook 44 secured on the distal end of a flexible
region 48. A stop 52 may provide a register to correctly position
the anchor 16 with respect to the receiver 18. When the anchor 16
is inserted to the stop 52, a hook 44 may engage an engagement
location 30 of the receiver 18.
[0072] Referring to FIG. 10, the length 28 (see FIG. 2) of the
engagement mechanism 24 may be selected to best match the
particular application to which the engagement mechanism 24 may be
applied. For example, the installation of a light fixture 12 may be
simplified by employing a comparatively long anchor 16 having a
similarly long engagement mechanism 24. In such an application, two
long anchors 16 may be secured to the fixture 12. The anchors 16
may be introduced into the corresponding receivers 18 a distance
sufficient to engage the engagement mechanisms 39 thereof. The
anchors 16 may then hold the fixture 12 in place while the
installer proceeds to connect the necessary wires 54. Upon
completion of the connecting of the wires 54, the fixture 12 may be
pushed in a transverse direction 11c until a proper position is
achieved. Thus, the installer need not hold the fixture 12 while
connecting wires 54 and tightening terminal screws 56.
[0073] Referring to FIG. 11, a receiver 18 may be associated with a
connection box 14 in any suitable manner. In selected embodiments,
the receiver 18 may be formed as an integral part of the connection
box 14. This forming may be part of a molding process. That is, the
receiver 18 may be molded as part of the connection box 14 in its
original forming process. FIG. 11 illustrates an embodiment in
which the receiver 18 is formed by stamping selected shapes from a
metal connection box 14 and then bending the cut portions in a
selected direction to form a guide 57 and an engagement mechanism
39. In an alternative embodiment, a receiver 18 may be formed (e.g.
molded, extruded, cast, machined, stamped, or the like) and then
joined to the connection box 14. Such a joining may be accomplished
by bolting, screwing, welding, gluing, bonding, or the like.
[0074] Referring to FIG. 12, connection boxes 14 are typically
installed and wired before the installation of the wall paneling
(e.g., ceiling paneling and the like). Fixtures 12 and face plates
20 are typically installed after the installation of the wall
paneling. The installation of wall paneling often involves the
application of dry wall compound. It is very common for clumps of
dry wall compound to be inadvertently introduced inside a
previously installed connection box 14. Receivers 18 in accordance
with the present invention may be formed in a manner to greatly
limit the adverse effects of misplaced dry wall compound.
[0075] For example, if dry wall compound were placed in the
receiver entrance 58, the receiver may be formed to have an open
back exit 59. Thus, anchor 16 may be inserted into the receiver 18
and any clump of dry wall compound may simply be pushed out the
back 59 of the receiver 18. The back 59 may be open to the exterior
of the connection box 14. The back 59 may also be configured to
open to the interior of the connection box 14. In such a
configuration, a dry wall compound clump will be pushed to the
interior of the connection box 14 where it can do no harm.
[0076] Embodiments in accordance with the present invention may be
applied to any unit 12 for which permanent or removable securement
to a connection box 14 is desired. Data terminals such as phone
jacks, network jacks, cable connections, and the like may not have
a fixture 12 associated therewith. These applications may deliver a
transmission line to a jack 60 or connector 60 mounted directly in
a face plate 20. The face plate 20 provides the structure and
support for the jack 60, and indeed may provide many of the same
functions as a fixture 12. Typically these face plates have been
secured directly to a corresponding connection box by multiple
screws. Installation of such screws presents difficulties similar
to those encountered in the installation of fixtures 12.
[0077] FIG. 12 illustrates one embodiment of a jack connection box
assembly 10 in accordance with the present invention. Interface
members 62a, 62b may provide an interface between a face plate 20
and anchors 16a, 16b. In selected embodiments, the interface
members 62 may include an aperture 64 to accommodate securement of
an anchor 16. Additional apertures 66 may provide locations for the
face plate 20 to engage the interface members 62. In certain
embodiments, extensions 68 or "dog ears" 68 may be incorporated to
hold each interface member 62 flush with the wall paneling.
[0078] The interface members 62 may be formed in any suitable shape
for providing adequate engagement between an anchor 16 and a face
plate 20. In one embodiment, the interface members 62 are generally
flat pieces having multiple apertures 64, 66 and extensions 68. The
interface members 62 may be constructed of any suitable material.
In selected embodiments, interface members 62 may be formed by
stamping sheet metal. In alternative embodiments, interface members
62 may be molded from a polymer, a composite, or the like.
[0079] Referring to FIGS. 13-15, as discussed hereinabove, after
the installation of a fixture 12, a face plate 20 is typically
secured thereto to hide the under workings from view. Conventional
face plates 20 are often secured by at least one screw. Screws and
other securement devices may be unsightly. Screws used to secure
face plates 20 to receptacles and switches are typically painted
and are, therefore, exposed to chipping, tarnishing, wear,
oxidation, and the like. In such applications, it may be desirable
to provide a snap-on assembly to provide fast securement of a face
plate 20 without the use of screws.
[0080] FIGS. 13-15 illustrate one embodiment of a screwless face
plate 20 in accordance with the present invention. In selected
embodiments, a face plate 20 may include engagement prongs 70. The
engagement prongs 70 may engage a fixture 12 and maintain the face
plate 20 aligned and secured thereto. Thus, once a face plate 20
has been attached, a complete fixture 12 assembly may be quickly
and easily wired and then secured to a corresponding connection box
14.
[0081] Selected fixtures 12 in accordance with the present
invention may include flanges 72. Flanges 72a, 72b may extend away
from a main body 74 of a fixture 12 in a longitudinal direction
11a. In selected embodiments, the flanges 72 may include an
aperture 64 to accommodate the securement of an anchor 16.
Additional apertures 66 may provide locations for the engagement
prongs 70 of the face plate 20 to engage the flanges 72. In certain
embodiments, extensions 68 or "dog ears" 68 may be selected to hold
the fixture 12 flush with the wall paneling.
[0082] Engagement prongs 70 in accordance with the present
invention may be formed to have multiple hooks 76a, 76b, 76c, 76d.
The hooks 76 may be secured to the face plate 20 by flexible necks
78a, 78b, 78c, 78d, respectively. A flex clearance 80 may be
provided between the hooks 76 so that as the prong 70 is inserted
through an aperture 66, the hooks 76 may deflect toward each other,
thus, effectively reducing the diameter of the prong 70. Once the
prong 70 has passed through the aperture 66, the hooks 76 may
return to their neutral position and engage the edges of the
aperture 66.
[0083] Referring to FIGS. 16 and 17, in selected embodiments, the
hooks 76 may be shaped to release at a desired removal loading,
thus, once the face plate 20 is removed, the face plate 20 may be
used again. For example, the hooks 76 may be provided with an
inside taper 82. The inside taper 82 may allow each hook 76 to
gradually flex and bend towards the flex clearance 80 as the face
plate 20 is pulled away from the fixture 12 so that the effective
diameter of the engagement prong 70 may be reduced and the prong 70
may be removed from the aperture 66. In an alternative embodiment,
a face plate 20 in accordance with the present invention may be
removed by applying sufficient force to fail the hooks 66.
[0084] A screwless face plate 20 in accordance with the present
invention may be formed of any suitable material. This material may
be selected based on several characteristics including cost,
aesthetics, dielectric constant, thermal capacity, strength,
toughness, flexibility, formability, and the like.
[0085] Engagement prongs 70 in accordance with the present
invention may have any suitable configuration. The number of prongs
70 may range from one to several and be selected to provide a
balanced securement between a face plate 20 and a fixture 12. The
number of hooks 76 making up each prong 70 may also range from one
to several depending on a desired engagement strength, ease of
manufacture, ease of installation, ease of removal, and the like.
In certain embodiments, the engagement strength may be balanced
with a desired release loading. The general shape or contour of the
prongs 70 may also be selected to provide a desired engagement
strength, ease of manufacture, ease of installation, ease of
removal, and the like.
[0086] Referring to FIGS. 18-20, alternative embodiments in
accordance with the present invention may employ alternative
methods for securing a screwless face plate 20 to a fixture 12. In
one alternative embodiment, a flange 72a of a fixture 12 may have
an engagement lip 84 formed therein. A extension 86 may be formed
in association with a corresponding face plate 20. The engagement
lip 84 may be configured to fit behind the extension 86 to hold the
upper portion of the face plate 20 to the flange 72a.
[0087] An aperture 66 may be formed in a flange 72b of the fixture
12. A corresponding engagement prong 70 may be formed in
association with the face plate 20. The prong 70 illustrated in
FIGS. 18-19 is an example of a single hook, rectangular prong 70.
The aperture 66 may be shaped to correspond to the design of the
prong 70. In selected embodiments, the lip 84/extension 86 and
aperture 66/prong 70 combinations may cooperate to secure the face
plate 20 to the fixture 12. Such an embodiment may be installed by
first inserting the lip 84 behind the extension 86 and then
rotating the face plate 20 down against the fixture 12 until the
prong(s) 70 may be inserted into the corresponding aperture(s) 66.
The prong 70 engagement may provide a tie to resist the tendency of
the lip 84 to disengage from the extension 86.
[0088] An engagement lip 84 in accordance with the present
invention may be divided into multiple engagement lips 84. In
selected embodiments, an upper flange 72a may be formed into two
lips 84a, 84b. The lips 84a, 84b may be separated by a notch 88. A
stop 90 may be formed as part of a corresponding extension 86. The
stop 90 may fit into the notch 88 to prevent lateral motion between
the upper flange 72a and the face plate 20.
[0089] In certain embodiments, ends 92 may form an enclosure 94 in
combination with an extension 86 and corresponding face plate 20.
The ends 92 may function to laterally retain the lip 84 of a flange
72a, when assembled.
[0090] In selected embodiments, a face plate 20 in accordance with
the present invention may have an access notch 96. In certain
embodiments, an access notch 96 may simply provide a hold to permit
the application of force to "pop" a face plate 20 from a
corresponding fixture 12. In alternative embodiments, the access
notch 96 may provide access behind the face plate 20 to a slender
tool. The slender tool may then be used to assist in the release of
an engagement prong 70.
[0091] Referring to FIG. 21, an alternative embodiment of an
engagement between a screwless face plate 20 and a fixture 12 may
involve the engagement of an edge 98 of the flanges 72 of the
fixture 12. One or more of the engagement prongs 70 of the face
plate 20 may be configured to engage an edge 98. In selected
embodiments, the prongs 70 may be formed to have a hook 76 and a
flexible neck 78. In certain embodiments, a flange 72 may include a
formation 100 to resist motion in a longitudinal direction 11a of a
face plate 70 with respect thereto. Such a formation 100 may be
formed by bending, cutting and bending, notching, or similarly
modifying the edge 98 to resist sliding of a prong 70 therealong in
a longitudinal direction 11a.
[0092] Referring to FIG. 22, an alternative embodiment of an
engagement between a screwless face plate 20 and a fixture 12 may
involve an engagement between a face plate 20 and an interface 104
of a fixture 12. Typically, the interface 104 of a fixture 12
extends a selected distance 106 to provide a flush joint with a
face plate 20. That is, the interface 104 extends to provide a
facing 108 that may be substantially coplanar with a surface 110 of
the face plate 20, thereby improving aesthetic appeal. The area of
the facing 108 may be selected to correspond to a selected
interface 104. Power outlet plugs 104 provide a relatively large
surface area. In contrast, switches 104 typically have a toggle
central unit and a thin border providing minimal surrounding facing
108.
[0093] The extension distance 106 of the electrical interface 104
provides the surface (substantially perpendicular to the facing
108) of an edge 102. An edge 112 of an aperture 114 (the aperture
114 may admit the interface 104 throUgh the face plate 20) may be
configured to engage the edge 102 of the interface 104. This
engagement may be of any suitable form. For example, the engagement
may involve any suitable combination of tabs, recesses, hooks,
shoulders, and the like.
[0094] In selected embodiments, the engagement between the edges
102, 112 may involve tabs 116 formed on the face plate 20 and
recesses 118 formed in the interface 104. The shape, number, and
location of these corresponding pairs may be selected to provide a
desired engagement strength, magnitude, and balance. Engagement
strength refers to the amount of force required to apply and secure
the face plate 20 to the fixture 12 or, alternatively, the force
required to separate the face plate 20 from the fixture 12. The
engagement strength may be selected to provide fast "snap-on"
assembly without risking inadvertent removal of the face plate 20
and possible electrical shock resulting therefrom.
[0095] Referring to FIGS. 23 and 24, an adapter 120 may be provided
to convert or retrofit a conventional fixture 12 to receive a
screwless face plate 20. In selected embodiments, an adapter 120 in
accordance with the present invention may include an aperture 122
corresponding to aperture 64 of a flange 72. A fastener 22 used to
secure an anchor 16 to a fixture 12 may also pass through the
aperture 122 to hold an adapter 120 in place against the flange 72.
The adapter 120 may extend to provide apertures 68 for admitting
the prongs 70 of a corresponding face plate 20. In this manner, a
snap-on, screwless face plate 20 may be retrofitted to typical
power receptacles and switches.
[0096] An adapter 120 in accordance with the present invention may
be formed of any suitable material. In selected embodiments, the
adapter 120 may be formed by stamping sheet metal. In an
alternative embodiment, the adapter 120 may be a molded polymer or
composite.
[0097] From the above discussion, it will be appreciated that the
present invention provides an apparatus and method for fast and
simple connection box assembly without screw rotation and the time
associated therewith. An embodiment in accordance with the present
invention may provide an apparatus for securing a fixture to a
connection box. In a factory manufacturing process an anchor may be
secured to a fixture. The anchor may have an engagement mechanism
formed therewith. A connection box may be provided to house wires
proceeding from a source to terminate therein. A receiver may be
associated with the connection box. The receiver may have an
engagement mechanism formed to receive and retain the engagement
mechanism of the anchor. Thus, the anchor and receiver may be
intermediaries in the securement of the fixture to the connection
box. Face plates in accordance with the present invention may have
engagement prongs. These prongs may be inserted through apertures
in a corresponding fixture to maintain the face plate aligned
securely thereagainst. A face plate may be installed by simply
pressing the engagement prongs through the appropriate apertures in
the fixture. Once a fixture has been wired and a face plate applied
thereto, the resulting assembly may be secured to the connection
box by inserting one or more of the attached anchors into
corresponding receivers associated with the connection box. The
anchor may be inserted a depth into the receiver selected to
properly position the face plate. Insertion of an anchor into a
receiver may be accomplished without the aid of tools.
[0098] The present invention may be embodied in other specific
forms without departing from its spirit or essential
characteristics. The described embodiments are to be considered in
all respects only as illustrative, and not restrictive. The scope
of the invention is, therefore, indicated by the appended claims,
rather than by the foregoing description. All changes that come
within the meaning and range of equivalency of the claims are to be
embraced within their scope.
* * * * *