Flangeless Speaker Mount Panel with Minimal Rim
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Solution Overview
Problem
Current flush mounting techniques for wall-mounted speakers are difficult to install in finished walls, prone to defects in size and positioning, and reduce available space for the speaker housing.
Innovation Solution
A flangeless speaker mounting system where the panel has a small rim extending outward from the wallboard, allowing for flexible positioning and installation, with a bracket and spackle shield to hide the joint, enabling easier installation and greater space for the speaker housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If traditional flush mounting techniques are used with a rim extending from the wallboard, then the speaker can be mounted flush to the wall, but the installation becomes extremely difficult in finished walls and defects in size or positioning are readily observable
Solution Approach 1:
The mounting system is divided into separate components: a receiver mounted to the wallboard, a panel with an opening that fits into the receiver, and a speaker housing. This segmentation allows each component to be installed and positioned independently, making installation in finished walls feasible while maintaining flush mount appearance.
Solution Approach 2:
The receiver acts as an intermediary component between the wallboard and the panel. It provides a mounting interface that allows the panel to be securely attached to the wallboard without requiring direct attachment, thereby facilitating installation in finished walls while maintaining the flush mount appearance.
2Shape
If the panel is placed behind the wallboard with a rim extending above it, then flush mounting is achieved, but the available space for the speaker housing is reduced
Solution Approach 1:
Instead of placing the panel behind the wallboard with a rim extending above it, the invention inverts the approach by mounting the receiver to the wallboard and having the panel fit into the receiver. This allows the speaker housing to extend forward from the panel, providing adequate space while achieving flush mount appearance.
3Strength
If the rim extends significantly from the panel, then it provides structural support, but it creates visible defects and reduces aesthetic appeal
Solution Approach 1:
The receiver provides structural support at the critical location where the panel meets the wallboard, while the panel itself has a minimal or no rim extension. This localized support structure maintains both structural integrity and aesthetic appearance by concentrating the support function where it is most needed.
Data Source
AI summary
A flangeless mounting system, suitable for in-wall speakers and other objects, includes a panel that replaces a substantial section of wallboard instead of being installed behind the wallboard. In preferred embodiments a rim extends outwardly from a first surface of the panel by a distance of less than ½ inch, and preferably by only ⅛ inch or even 1/16 inch. The face of the object can be quite large, up to 40 in2 or more, and still be relatively small with respect to the panel. Panels are contemplated that have a width at least two, three or more times that of the face of the object, and along with optional wings are wider than the stud separation in the wall.