Self-adjusting frame for mounting over a wall-mounted electrical device

• US 10,410,802 B2
• Filed: 03/24/2017
• Issued: 09/10/2019
• Est. Priority Date: 03/24/2016
• Status: Active Grant

• Current Assignee: Lutron Technology Company LLC
• Original Assignee: Lutron Technology Company LLC
• Inventors: Dimberg, Chris, McDonald, Matthew Philip
• Primary Examiner(s): Barnie, Rexford N
• Assistant Examiner(s): Ly, Xuan
• Application Number:
  US15/468,661
• Publication Number:
  US 20170278647A1
• Time in Patent Office: 900 Days
• Field of Search: 307143
• CPC Class Codes: H01H 11/00 Apparatus or processes specially adapted for the manufacture of electric switches processes specially adapted for manufacture of rectilinearly movable switches having a plurality of operating members associated with different sets of contacts, e.g. keyboards, H01H13/88
• CPC Class Codes: H01H 2223/034 Bezel
• CPC Class Codes: H01H 23/16 Driving mechanisms
• CPC Class Codes: H01H 2300/03 Application domotique, e.g. for house automation, bus connected switches, sensors, loads or intelligent wiring
• CPC Class Codes: H01H 9/02 Bases, casings, or covers accommodating more than one switch or a switch and another electrical component H02B1/26
• CPC Class Codes: H01H 9/0207 Adjustable mounting of casings
• CPC Class Codes: H01H 9/0235 specially adapted for remote control, e.g. of audio or video apparatus
• CPC Class Codes: H01H 9/025 Stands or organisers to facilitate location or operation
• CPC Class Codes: H01H 9/287 wherein the operating part is made inaccessible or more difficult to access by a lid, cover or guard, e.g. lockable covers
• CPC Class Codes: H02G 3/14 Fastening of cover or lid to box
• CPC Class Codes: H03K 17/962 Capacitive touch switches
• CPC Class Codes: H05B 45/00 Circuit arrangements for operating light-emitting diodes [LED]
• CPC Class Codes: H05B 47/10 Controlling the light source
• CPC Class Codes: H05B 47/19 via wireless transmission
• CPC Class Codes: Y02B 90/20 Smart grids as enabling technology in buildings sector smart grids supporting the management or operation of end-user stationary applications in general, or like technologies with no associated climate change mitigation effect Y04S20/00
• CPC Class Codes: Y04S 20/14 Protecting elements, switches, relays or circuit breakers

Abstract

A mounting frame may be configured as a self-adjusting mounting frame that biases itself against a surface of structure. The mounting frame may be a component, for example, of a remote control device or a faceplate assembly. The mounting frame may be configured to bias a rear surface of the mounting frame against the surface of a structure. The mounting frame may include biasing members. Each biasing member may include an attachment portion and a pair of resilient spring arms that suspend the attachment portion relative to a perimeter wall of the mounting frame such that the attachment portion is spaced further from the rear surface of the mounting frame than locations where the spring arms extend from the mounting frame. The rear surface of the mounting frame may be defined by the perimeter wall.

Claims

1. A remote control device that is configured for use in a load control system having a load control device, the load control device configured to control an amount of power delivered to an electrical load that is electrically connected to the load control device, the remote control device comprising:

a mounting frame that is configured to be attached to a yoke of a mechanical switch installed in a wallbox, wherein the mechanical switch controls whether power is delivered to the electrical load;

a control unit that is configured to be attached to the mounting frame, the control unit including a control interface and a wireless communication circuit, the control unit configured to translate a user input from the control interface into a control signal that controls the load control device, the control unit further configured to cause the wireless communication circuit to transmit the control signal; and

a faceplate that is configured to be attached to the mounting frame, the faceplate having an opening that is configured to receive at least a portion of the control interface,

wherein the mounting frame includes a biasing member that extends inward from a perimeter wall of the mounting frame, the biasing member configured to bias a rear surface of the mounting frame against an outer surface of a structure that surrounds the wallbox, and

wherein the biasing member includes an attachment portion and a pair of resilient spring arms that suspend the attachment portion relative to the perimeter wall of the mounting frame such that the attachment portion is spaced outward relative to the rear surface of the mounting frame.

2. The remote control device of claim 1, wherein the biasing member is configured to bias the rear surface of the mounting frame against the outer surface of the structure as the mounting frame is fastened to the yoke of the mechanical switch.

3. The remote control device of claim 2, wherein the attachment portion defines an aperture that is configured to receive a faceplate screw to secure the attachment portion against the yoke of the mechanical switch.

4. The remote control device of claim 3, wherein the mounting frame includes a first pair of tabs that extend inward from the perimeter wall, and wherein each spring arm extends from the attachment portion to a respective one of the first pair of tabs.

5. The remote control device of claim 4, wherein the biasing member is configured such that the attachment portion is spaced further from the rear surface of the mounting frame than respective locations where the first pair of tabs extend from the perimeter wall.

6. The remote control device of claim 5, wherein the biasing member is a first biasing member, and wherein the mounting frame further includes a second resilient biasing member that is configured to cooperate with the first biasing member to bias the rear surface of the mounting frame against the outer surface of the structure.

7. The remote control device of claim 6, wherein the second biasing member includes a second attachment portion and a second pair of resilient spring arms that suspend the second attachment portion relative to the perimeter wall of the mounting frame, the second attachment portion defining a second aperture that is configured to receive a second faceplate screw to secure the attachment portion against the yoke of the mechanical switch.

8. The remote control device of claim 7, wherein the mounting frame includes a second pair of tabs that extend inward from the perimeter wall, and wherein each spring arm of the second pair of spring arms extends from the second attachment portion to a respective one of the second pair of tabs.

9. The remote control device of claim 8, wherein the second biasing member is configured such that the second attachment portion is spaced further from the rear surface of the mounting frame than respective locations where the second pair of tabs extend from the perimeter wall.

10. The remote control device of claim 9, wherein the first and second biasing members are configured such that the first and second attachment portions are equally spaced from the rear surface of the mounting frame.

11. The remote control device of claim 10, wherein the first and second biasing members are configured such that, as the mounting frame is attached to the yoke of the mechanical switch, respective faceplate screws pull the first and second attachment portions toward the structure, thereby causing the first and second pairs of spring arms to bias the rear surface of the mounting frame against the outer surface of the structure.

12. The remote control device of claim 6, wherein the first biasing member is located at an upper end of the perimeter wall and the second biasing member is located at a lower end of the perimeter wall.

13. The remote control device of claim 5, wherein the pair of spring arms define respective curved geometries between the first pair of tabs and the attachment portion.

14. The remote control device of claim 5, wherein the first pair of tabs and the pair of spring arms are sloped between the perimeter wall and the attachment portion.

15. The remote control device of claim 4, wherein the perimeter wall of the mounting frame defines four corners, and wherein the first pair of tabs are located in opposed corners at an upper end of the perimeter wall.

16. A mounting frame that is configured to be attached to an installed mechanical switch that controls whether power is delivered to an electrical load, the mounting frame comprising:

first and second biasing members that are configured to bias a rear surface of the mounting frame against an outer surface of a structure to which the mechanical switch is mounted;

an opening that is configured to surround a bezel of the mechanical switch when the mounting frame is attached to a yoke of the mechanical switch; and

a perimeter wall that defines the rear surface of the mounting frame,

wherein the first biasing member comprises a first pair of resilient spring arms that extend from the perimeter wall into the opening and a first attachment portion that is suspended by the first pair of spring arms such that the first attachment portion is spaced outward relative to the rear surface of the mounting frame, and wherein the second biasing member comprises a second pair of resilient spring arms that extend from the perimeter wall into the opening and a second attachment portion that is suspended by the second pair of spring arms such that the second attachment portion is spaced outward relative to the rear surface of the mounting frame.

17. The mounting frame of claim 16, wherein the first attachment portion defines a first aperture that extends therethrough and the second attachment portion defines a second aperture that extends therethrough, the first and second apertures configured to receive respective faceplate screws that secure the first and second attachment portions to the yoke of the mechanical switch.

18. The mounting frame of claim 17, wherein the biasing members are configured such that, as the mounting frame is attached to the yoke of the mechanical switch, the faceplate screws cause the first and second attachment portions toward the outer surface of the structure, thereby causing the first and second pairs of spring arms to bias the rear surface of the mounting frame against the outer surface of the structure.

19. The mounting frame of claim 16, wherein the first biasing member is configured to receive a first faceplate screw and the second biasing member is configured to receive a second faceplate screw, and wherein the first and second biasing members cooperate to bias the rear surface of the mounting frame against the outer surface of the structure as the first and second faceplate screws are driven into corresponding screw holes of the yoke of the mechanical switch.

20. A faceplate assembly comprising:

a mounting frame that is configured to be attached to a yoke of a wall-mounted control device installed in a wallbox, wherein the mounting frame comprises a mounting frame opening that is configured to surround a bezel of the wall-mounted control device when the mounting frame is attached to the yoke of the wall-mounted control device, and wherein the mounting frame comprises a perimeter wall that defines a rear surface of the mounting frame, and wherein the mounting frame includes a biasing member that is configured to bias a rear surface of the mounting frame against an outer surface of a structure that surrounds the wallbox, and wherein the biasing member includes an attachment portion and a pair of resilient spring arms that suspend the attachment portion relative to the perimeter wall of the mounting frame such that the attachment portion is spaced outward relative to the rear surface of the mounting frame, the attachment portion defining an aperture that is configured to receive a faceplate screw to secure the attachment portion against the yoke of the wall-mounted control device; and

a faceplate that is configured to be attached to the mounting frame, the faceplate having a faceplate opening that is configured to receive at least a portion of a control interface that controls an amount of power delivered to an electrical load.

21. The faceplate assembly of claim 20, wherein the control interface is defined by a control unit that is configured to be attached to the mounting frame, the control unit including a wireless communication circuit, the control unit configured to translate a user input received by the control interface into a control signal that controls the amount of power delivered to the electrical load, the control unit further configured to cause the wireless communication circuit to transmit the control signal.

22. The faceplate assembly of claim 21, wherein the wall-mounted control device comprises a mechanical switch.

23. The faceplate assembly of claim 20, wherein the wall-mounted control device defines the control interface.

24. The faceplate assembly of claim 20, wherein the biasing member is configured to bias the rear surface of the mounting frame against the outer surface of the structure as the mounting frame is fastened to the yoke of the wall-mounted control device.

25. The faceplate assembly of claim 20, wherein the attachment portion defines an aperture that is configured to receive a faceplate screw.

26. The faceplate assembly of claim 20, wherein the biasing member is configured such that the attachment portion is spaced further from the rear surface than respective locations where the pair of spring arms extend from the perimeter wall.