Flangeless In-Wall Speaker Mounting Panel
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Solution Overview
Problem
Conventional methods for mounting components like plasma screens, speakers, and electrical outlets in walls and ceilings result in gaps that require finishing, which can be challenging to make flush with the surrounding surface, especially when aiming for a seamless appearance.
Innovation Solution
A panel and receiver assembly where the panel is significantly larger than the opening, allowing for a flush-mount installation with minimal to no finishing required around the periphery, using a receiver that is securely attached to the panel and can be finished away from the component, enabling easier and more accurate surface integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional mounting methods with brackets and flanges are used, then components can be securely mounted in walls and ceilings, but gaps are created between the component and surrounding surface requiring finishing work
Solution Approach 1:
The mounting system is divided into separate functional elements: a mounting bracket secured to the component, and a separate panel with an opening that receives the bracket. This segmentation allows the panel to be finished independently away from the component, eliminating the need for difficult finishing work around the component periphery while maintaining secure mounting through the bracket-panel connection.
Solution Approach 2:
The panel acts as an intermediary element between the mounting bracket and the wall/ceiling surface. Instead of directly finishing around the bracket or component, the panel provides a intermediate surface that can be finished away from the component, with the finishing work occurring on the panel itself rather than in the constrained space around the component.
2Manufacturing precision
If the panel is made significantly larger than the opening, then finishing can be performed away from the component for better appearance, but the amount of material and complexity increases
Solution Approach 1:
The solution moves the finishing operation to a different spatial dimension - instead of finishing horizontally around the component opening, the panel extends in the depth dimension (into the wall/ceiling space), allowing finishing to occur on the panel surface away from the component while maintaining a compact overall profile.
Data Source
AI summary
A flangeless mounting system, suitable for in-wall speakers and other components, includes a panel that is finished to provide at least a superficially continuous junction between the edges of the panel and the surrounding wall, ceiling, or other structure. A rim advantageously extends outwardly from a first surface of the panel by a small distance, which in currently preferred embodiments is about 1/16th inch to ⅛th inch,. A collar is preferably installed about the inner edge of the opening, and a receiver is attached to the collar or directly to the panel. Magnetic, threaded, detent, and frictional means are contemplated for maintaining the component in position relative to the receiver.