WO2010070376A1

WO2010070376A1 - Mounting system for electrical devices

Info

Publication number: WO2010070376A1
Application number: PCT/IB2008/003549
Authority: WO
Inventors: William Randall; Daniel Ontiveros; Octavio Salvador Galindo Aragon
Original assignee: Leviton Manufacturing Co., Inc.; Gandara Romano, Normando
Priority date: 2008-12-19
Filing date: 2008-12-19
Publication date: 2010-06-24
Also published as: MX2009009107A; UY32201A

Abstract

The present invention describes an innovative mounting system for wall-mounted electrical devices. This system comprises: a cover plate, a mounting plate with a central window wherein at least one electrical device is located. Each module has on each of its side faces front projections and a rear projection. The projections are attached to a lip running through each side inner wall of the inner frame projected of said central window of the support of the present invention. Likewise, the mounting plate also has fork-shaped holders which are easily manufactured and are used to temporally hold the mounting means during storage, packaging and transportation until the mounting means are removed by the final user to employ them for installing the final product.

Description

MOUNTING SYSTEM FOR ELECTRICAL DEVICES

TECHNICAL FIELD

The present invention is related to field of the installation of wall-mounted electrical devices. Particularly, this invention focuses on a new mounting system for said electrical devices.

Throughout this specification, "electrical device" is understood as comprising any type of wall- mounted electrical device. This term includes, but is not limited to: blank modules, electrical sockets, data modules, telephone modules, cable modules, TV modules, switches, buttons, pushbuttons, doorbells, lighting controls, air conditioning controls, connectors, regulators, buzzers, timers, keys, cover plates, occupancy sensors, fan speed controllers, or the like

BACKGROUND OF THE INVENTION

Currently, there is a great diversity of mounting systems for wall-mounted electrical devices.

Generally, all these systems include the following elements: a cover plate, support frame, and at least one electrical device.

The international patent publication WO2006/106553 refers to a support frame for housing at least one electrical apparatus, the support frame houses an optical source within its structure, controlled by an electrical circuit in order to illuminate the whole mounting system. That invention is limited to said optical source and has the disadvantage that the additional essential elements comprising it are expensive, and make its manufacture difficult to achieve. Even though the subject-matter protected by said document is limited to the optical source, side walls located on the support frame, inside the main opening, are shown in the Figures. Said walls have a "zigzag" patterned edge, which allows the engagement of various electrical devices. Said edge presents a disadvantage in that manufacturing of the same includes an excess of material. Also, the zigzag pattern form presents various technical obstacles during manufacture of the support frame. The United States Patent Application Serial

Number US 11/910,890 describes a , support frame having several coupling channels acting together with several coupling tabs in the cover plate, in order to attach both pieces. Likewise, even though the protection in the document is limited to the optical source, side walls located on the support frame, inside of the main opening, are shown in the Figures. Said walls have a "zigzag" patterned edge, which allows the engagement of various electrical devices. Said edges present a disadvantage in that manufacturing of the same includes an excess of material. Also, the "zigzag" pattern form presents various technical obstacles during the manufacture of the support frame.

On the other hand, Spain Patent ES 2249945 protects improvements in assembling system consisting of a cover plate, a support frame and at least one electrical device. Said support frame presents a plurality of flanges and projections grouped in three groups on both side walls of a central opening, said groups comprising an inverse-trapezoid stepped edge with inverted "T" flanges located on its central part, as well y as a rectangular recess. The 'electrical devices have vertical flanges on both side faces, which slidingly engage the inner sides of the corresponding stepped edges and the vertical projections on the flange of the inner face of the support frame. In this manner, as the electrical device is lowered, the lower flanges located between vertical flanges are locked below the corresponding inverted "T" horizontal flange. Although it is true that the electrical device is firmly fixed and immobilized in its place of use, it is also true that this mounting system presents several disadvantages. In the first place, the rectangular recess that is joined to the support frame only at one of its sides can disengage or break due to material fatigue or an excessive force applied by the user during its installation. A second disadvantage is the technical complexity for manufacturing the support frame and the electrical device, which results in a high monetary cost. Finally, another technical disadvantage is that since the inner walls are not forming a solid inner frame, the latter is subject to possible structural breaking at mechanical stress concentration zones. It is important to point out that in the market and in the state-of-the-art there are other similar mounting systems based on cantilevered recesses weakly joined to the support frame at one side only, and the inner walls forming the inner frame housing the various electrical devices show the same technical disadvantages.

Additionally, Mexican Patent No. 232391 and Mexican Utility Model No. 1082 protect mounting support frames for wall-mounted electrical devices. In general terms, said support frames have inside the main housing opening: means for limiting the insertion of at least one electrical device; means to guide the insertion of at least one electrical device laterally protruding on each side of the mounting position, and a locking tab to releasable fix at least one electrical device, this tab is provided with an internal anterior tooth looking backwards. The locking tab is elastic and angularly deformable from a resting coupled operating position to an elastically deformed released position, in which the inner anterior backwards-looking tooth moves outwardly. In both cases, the locking tab and the inner support frame walls present the same disadvantages as mentioned in the previous paragraph. Finally, the Mexican Utility Model 1782 claims an electrical assembly for module/support mounting comprising a main rectangular perforation, inside which is defined an inner solid frame, wherein the walls of the frame having the larger length have slight extended side lips, as well as teeth above said lips. The electrical devices modules have two upper teeth and two lower lips, which engage with the support lips, generating four fixing points that prevent axial movements. The upper teeth prevent the module from sinking, while the lower lips prevent the module from disengaging due to the cables stress. The support teeth act as guides for the modules allowing then to be placed in up to five positions. Also, the support teeth together with the upper teeth prevent the axial movement of the module. One potential disadvantage of this type of support it is possible that a user places the module upside down because the teeth on the modules engage the support lips in any orientation. Also, it is foreseeable that the thin thickness of the two lower lips of the module could make them breakable or detachable. Additionally, as the support teeth could be prone to wearing out, the worn out teeth would not hold the modules in place against axial displacement. Finally, inclusion of these teeth in the support naturally leads to a potential excess of material in manufacturing the support.

In the market and in the state-of-the-art there are other mounting systems wherein the inner frame of the support has solid inner walls with simple vertical guides and the electrical device module can also be placed upside down. Based on the aforementioned, the state-of-the- art shows a need for a wall-mounting system based on a support for electrical devices wherein the inner frame is structurally reinforced against mechanical stress. Similarly, it is desirable to have a support for housing electrical devices that prevents the lateral movement of said devices and prevents the possibility of placing the electrical device in a wrong position. Finally, it is further desirable a new mounting system with the greatest possible material savings and keeping the system installation simple and straightforward.

DESCRIPTION OF THE DRAWINGS

In order to provide a better understanding of the invention, the following drawings are attached: Figure 1 refers to a right front top perspective view of the mounting plate for the mounting system of one embodiment of the present invention.

Figure 2 refers to a front view of the mounting plate for the mounting system of one embodiment of the present invention.

Figure 3 refers to a left rear inferior perspective view of the mounting plate for the mounting system of one embodiment of the present invention.

Figure 4 refers to a rear view of the mounting plate for the mounting system of one embodiment of the present invention. Figure 5 refers to a right side view of the mounting plate for the mounting system of one embodiment of the present invention.

Figure 6 refers to a left side view of the mounting plate for the mounting system of one embodiment of the present invention.

Figure 7 refers to a top view of the mounting plate for the mounting system of one embodiment of the present invention.

Figure 8 refers to a lower view of the mounting plate for the mounting system of one embodiment of the present invention.

Figure 9 refers to a left front top perspective view of a representative electrical device used with the mounting plate for the mounting system of one embodiment of the present invention.

Figure 10 refers to a front view of the mounting plate for the mounting system of one embodiment of the present invention.

Figure 11 refers to a left side view of the mounting plate for the mounting system of one embodiment of the present invention.

Figures 12A to 12F refers to left front top perspective views of some exemplary electrical devices used with the mounting plate for the mounting system of the present invention.

Figure 13 refers to a right front top perspective view of an assembly of the mounting system of one embodiment of the present invention.

Figure 14 refers to a right rear inferior perspective view of an assembly of the mounting system of one embodiment of the present invention.

In order to facilitate the understanding of the present invention, Table 1 list the reference numbers shown in the figures, and the components and characteristics to which they make reference in the Figures .

Table 1 - Reference numbers

NO. COMPONENT NO. COMPONENT

10 mounting plate 11, 12 flange

13, 14 tabs 15, 16 main mounting perforations

17, 18 alternative mounting 20 mounting plate front orifices surface

21, 23 openings 22, 24 ribs

25 central window 30 inner frame

31 lower inner wall of 32, 34 side inner walls of inner inner frame frame

33 top inner wall of inner 35 inner frame reinforcement frame

36, 37 side wall longitudinal 38, 39 coupling groove lip of inner frame

40 mounting plate rear 41, 43 mechanical mounting means surface holders

42, 44 truncated ribs 41a, notch 43a

41b, 43b fixing pins 41c, attachment side 43c

45 ribs 50 electrical device module

51 module front face 52 module top face

53 module side face 54 front mounting projections

54' front projections 55 rear mounting projection chamfer

55' rear projection chamfer 60 electrical device mounting system for wall-mounted electrical devices. As shown in the figures, the mounting system for one embodiment of the present invention comprises some elements in common with similar systems, said elements are: a cover plate, a mounting plate (10), and at least one electrical device module (50) .

Figures 1 to 8 illustrate the mounting plate (10) of the present mounting system described below. The mounting plate (10) has a front surface (20) on which a central window (25) is located; a rear surface (40) ; and an internal frame (30) formed by four walls projected perpendicularly backwards from the front surface (20) . The mounting plate also has flanges (11, 12) and tabs (13, 14) on its ends. Tabs (13, 14) are assembled to corresponding attachment projections (not shown) in the cover plate. Flanges (H, 12) are inserted in corresponding grooves (not shown) located in the ends of the cover plate in order to facilitate detachment of the cover plate and the mounting plate (10) . The mounting plate (10) further comprises main mounting perforations

(15, 16) to be used together with mechanical mounting means, such as screws, fasteners, rivets or other fastening means generally known to those in the art. to mount the mounting plate (10) on an embedded electric switchbox or junction box (not shown) . Additionally, the mounting plate (10) has alternative mounting orifices

(17, 18) used together with any mechanical mounting means, e.g., fasteners, to mount the mounting plate (10) in other type of mountings.

Referring to Figures 1 and 2, the mounting plate (10) also has longitudinal openings (21, 23) on its sides, which will be described below. The front surface (20) has ribs (22, 24) which serve as visual indicators to locate the electrical device modules (50) to their attachment place within the mounting plate (10 However, in an alternative embodiment, the ribs (22, 24) can also be located on the inner frame (30) longitudinal walls or on the central window (25) chamfer edges, wherein may serve to physically guide the electrical device modules (50) to their attachment place within the mounting plate (10) . Referring now to Figures 3 and 4, the rear surface (40) has ribs (45) that provide a greater structural resistance to the mounting plate (10) . The ribs have a characteristic form in order to protect the mounting plate (10) from mechanical stress concentration coming from the elements described thereof. Additionally, there are truncated ribs (42, 44) specially designed to provide non-fitting housing to mechanical mounting means (not shown) .

As seen in Figures 3, 7 and 8, the mounting plate (10) has holders (41, 43) located longitudinally on the sides perpendicular to the rear surface (40) plane, and projected rearwards. Said holders (41, 43) are used to adjustably and releasably hold mechanical mounting means for packing and transportation of the final product. Holders (41, 43) are formed from the same mounting plate (10), by means of a cut-out made in the plate by a stamping, die-cutting or molding operation. The structure resulting from this operation has a square form held by only one attachment side (41c, 43c) to the mounting plate (10) and the side opposed to the attachment presents a notch (41a, 43a), generating fixing pins (41b, 43b) . This way, holders (41, 43) are substantially "U"-shaped or fork-shaped. Then, holders (41, 43) are bent rearwards until they are substantially perpendicular with the rear surface (40) . Openings (21, 23) result as a consequence of the holders (41, 43) formation process. The main advantage of said holders

(41, 43) is the material savings and the ease of manufacturing them in the support (10) . Although the particular construction of the fasteners is described above, it should be noted that these fasteners can be constructed by any suitable manner.

The inner frame (30) of the mounting plate (10) is illustrated in Figures 1, 3, and 5 to 8. This component is formed by a lower inner wall (31), a left side inner wall (32), a top inner wall (33), and a right side inner wall (34) . Reinforcements (35) are projected rearwards from the inner frame (30) . Said reinforcements (35) are located in the corners formed in the union of the walls (31) , (32), (33) and (34) where there is a mechanical stress concentration. These reinforcements (35) give greater structural rigidity to inner frame (30) . Referring to Figures 1 to 4, each of the longitudinal walls (32, 34) of the inner frame (30) has a longitudinal lip on its inner surface (36, 37) . The longitudinal lip (36, 37) is projected inwards, runs end- to-end, and its thickness reaches the rear surface of the inner frame. The longitudinal lip (36, 37) has a plurality of coupling grooves (38, 39), preferably evenly separated and having the function described below. In the preferred embodiment of the present invention there are three coupling grooves (38, 39) in each longitudinal lip (36, 37) .

Figures 9 to 11 illustrate the electrical device module (50) . It must be noted that the illustrated module herein is, but is not limited to, a coaxial connection electrical device (60) for which only the orifice is shown. However, the electrical device may comprise other mechanisms as defined at the beginning of this specification. The electrical device module (50) is preferably formed by a housing similar in form to a parallelepiped comprising a front face (51) , a rear face (not shown), a top face (52), a bottom face (not shown) similar to the top face (52), and the two side faces (53) similar to each other. The front face (51) has means to attach the electrical device (60), which, as aforementioned, may include different mechanisms as previously defined. Figures 12A to 12F illustrate, without limiting, some of the electrical device modules (50) that may be used within the present invention.

Each side face (53) has two aligned frontal projections (54) and a rear projection (55), all of them projecting outwardly from the module (50) . Each front projection (54) presents on its front face a chamfer (54' ) and on its rear face a flat surface perpendicular to the side face (53) . The rear projection (55) has on its rear face a chamfer (55') and on its front face a flat surface perpendicular to the side face (53) .

In one embodiment, the mounting system of the present invention comprises the attachment of the mounting plate (10) to at least one electrical device module (50) . The mounting task starts when at least one electrical device module (50) is inserted into the central window (25) of the mounting plate (10) . The ribs (22, 24) serve as guides to insert the module (50) . The projections (54) and (55) located in the side walls (53) of the module (50) run tightly along the side inner walls (32) and (34) until reaching the lips (36) and (37) . The chamfers (55' ) located in the rear projections (55) help to slide said projections over the lips (36) and (37) . At the same time, the rear projections (55) are inserted within the coupling grooves (38) and (39) . This way, lips (36) and (37) are located in the area comprised between the rear projections (55) and front projections (54) of module (50), thus completing the installation. An exemplary illustration of the assembled mounting system can be found on figures 13 and 14.

It must be noted that this system does not allow the electrical device modules to easily detach because the walls of the lips (36) and (37) and the flat walls of projections (54) and (55) are in abutting relationship, thus preventing any movement in the front- rear directions. Likewise, the side faces of the rear projections (55) are in abutting relationship with the coupling grooves (38, 39), thus preventing them from slipping longitudinally over the lips (36, 37) . Therefore, one advantage of current embodiment of the mounting system of the present invention is a greater breaking-strength assembly.

Several advantages of this mounting system are the simplification of manufacturing molds, both for the mounting plate (10) and the electrical device modules

(50) , due at least in part to the manufacturing features which are included. Also, the mounting system elements provide for potential material savings, which result in a more efficient production. Both advantages allow logistic and economic benefits. Another advantage inherent to certain embodiments of the mounting system of the present invention is the improvement in preventing the user from wrongly attaching the modules since the modules are keyed. This makes the installation tasks easier, and prevents the user from damaging the components due to incorrect installation. Even though the invention has been described with reference to certain specific embodiments, the experts in this technical field will know about several modifications to it without departing from the purpose and field of application of the invention as described in the claims attached hereto.

Claims

CLAIMS :

1. A mounting system comprising a cover plate, a mounting plate on which a central window and an inner frame are located, and at least one electrical device module, wherein: the longitudinal side inner walls of the inner frame have longitudinal lips projected inwards and running from end-to-end; the electrical device module comprises a housing similar to a parallelepiped which front face comprises an electrical device; and each side face of the module has projections looking outwards the module; characterized in that: the longitudinal lips have a plurality of coupling grooves; and each side face of the module has two front projections and one rear projection.

2. The mounting system according to claim 1, wherein the mounting plate further has tabs and flanges at its ends which are attached with corresponding attachment means in the cover plate.

3. The mounting system according to claim 1, wherein the mounting plate further comprises main mounting perforations used together with a mechanical fasteners to mount the mounting plate in an embedded electrical switchbox.

4. The mounting system according to claim 1, wherein the mounting plate further comprises alternate mounting orifices used together with mechanical fasteners to mount the mounting plate in other types of mountings.

5. The mounting system according to claim 1, wherein the mounting plate further has ribs on its front surface which serve as visual indicators to locate one or more electrical devices to their attachment place upon mounting them.

6. The mounting system according to claim 1, wherein the mounting plate further has ribs located on the inner frame longitudinal walls or on the central window chamfer edges, wherein may serve to physically guide one or more electrical device modules to their attachment place within the mounting plate.

7. The mounting system according to claim 1, wherein the mounting plate further comprises ribs on its rear surface which have a characteristic form in order to protect the mounting plate from mechanical stress concentrations.

8. The mounting system according to claim 1, wherein the longitudinal lips thickness reaches up to the rear end of the inner frame.

9. The mounting system according to claim 1, wherein the mounting plate further comprises holders located substantially perpendicular to the rear surface plane and projected towards the rear part of the mounting plate .

10. The mounting system according to claim 9, wherein the holders are formed out of the same mounting plate .

11. The mounting system according to claim 10, wherein the holders are formed using a cut-out made in the plate by a stamping, die-cutting or molding operation.

12. The mounting system according to claim 10, wherein the holders are substantially "U"-shaped or fork- shaped, comprising a portion attached to the mounting plate, and the opposite side has a notch generating fixing pins.

13. The mounting system according to claim 9, wherein the mounting plate preferably has at least one holder on the rear surface plane of the mounting plate.

14. The mounting system according to claim 9, wherein the holders act together with truncated ribs in order to accommodate mechanical fasteners.

15. The mounting system according to claim 1, wherein reinforcements are projected rearwards from the inner frame, and are located in the corners formed by the union of the inner walls of the frame where there is a mechanical stress concentration, in order to provide a greater structural rigidity to the inner frame.

16. The mounting system according to claim 1, wherein the longitudinal lips have at least one coupling groove on each longitudinal lip.

17. The mounting system according to claim 1, wherein each front projection has on its front face a chamfer and on its rear face a flat surface perpendicular to the side face of the module.

18. The mounting system according to claim 1, wherein each rear projection has on its rear face a chamfer and on its front face a flat surface perpendicular to the side face of the module.

19. The mounting system according to claims 3,

4 or 14, wherein the mechanical fasteners can comprise: screws or rivets.

20. The mounting system according to claim 1, wherein the electrical device can comprise: blank modules, electrical sockets, data modules, telephone modules, cable modules, TV modules, switches, buttons, pushbuttons, doorbells, lighting controls, air conditioning controls, connectors, regulators, buzzers, timers, keys, cover plates, occupancy sensors, or fan speed controllers.

21. A mounting plate for mounting electrical devices characterized in that it has holders positioned substantially perpendicular to the rear surface plane of the mounting plate, and projected towards its rear part.

22. The mounting plate according to claim 21, wherein the holders are formed out from the same support.

23. The mounting system according to claim 22, wherein the holders are formed using a cut-out made in the plate by a stamping, die-cutting or molding operation.

24. The mounting plate according to claim 22, wherein the holders are substantially "U"-shaped or fork- shaped, comprising a portion attached to the mounting plate and the opposite side has a notch generating fixing pins .

25. The mounting plate according to claim 21, wherein the holders act together with truncated ribs in order to house mechanical fasteners.

26. The mounting plate according to claim 21, wherein the mounting plate preferably has two holders on its longitudinal sides.

27. The mounting plate according to claim 25, wherein the mechanical fasteners can comprise screws or fasteners .