Recessed thermostat and cutting tool

• US 8,671,702 B1
• Filed: 09/16/2009
• Issued: 03/18/2014
• Est. Priority Date: 09/16/2008
• Status: Active Grant

• Current Assignee: Hubbell, Inc.
• Original Assignee: Hubbell, Inc.
• Inventors: Shotey, Marcus J., Baldwin, Jeffrey P., Booth, Kenneth C.
• Primary Examiner(s): Vo, Peter DungBa
• Assistant Examiner(s): PARVEZ, AZM A
• Application Number:
  US12/561,203
• Time in Patent Office: 1,644 Days
• Field of Search: 295/250.1, 294/28, 295/92, 236/9.A, 236/1.C, 236/91.R, 236/91.E, 236/91.F, 345/684, 700/299, 621/29
• US Class Current: 62/129
• CPC Class Codes: B23D 45/003 for particular purposes
• CPC Class Codes: B28D 1/041 with cylinder saws, e.g. trepanning; saw cylinders, e.g. having their cutting rim equipped with abrasive particles
• CPC Class Codes: Y10T 29/49 Method of mechanical manufacture
• CPC Class Codes: Y10T 29/49947 by applying separate fastener

Abstract

In an aspect, a recessed thermostat assembly includes a thermostat housing having a face plate and one or more side walls at least partially enclosing one or more thermostat components. The face plate is wider than the side walls. A moveable brace is responsive to and operatively associated with a brace actuator such that movement of the brace actuator in a first direction responsively causes the moveable brace to move toward the face plate, and movement of the brace actuator in a second direction responsively causes the moveable brace to move away from the face plate. The brace actuator accessible through the face plate. The movable brace is configured to impinge a building wall structure between the movable brace and a rear surface of the face plate when the moveable brace is moved toward the face plate.

Claims

1. A recessed thermostat assembly, comprising:

a thermostat housing comprising a face plate and a circular side wall extending from a rear surface of the face plate, the thermostat housing at least partially enclosing one or more thermostat components;

a moveable brace responsive to a brace actuator, the brace actuator accessible through the face plate and operatively associated with the moveable brace such that movement of the brace actuator in a first direction responsively causes the moveable brace to move linearly toward the face plate and impinge a building wall structure between the moveable brace and the rear surface of the face plate when the circular side wall is mounted within a circular mounting hole opening on the building wall structure, and movement of the brace actuator in a second direction responsively causes the moveable brace to move away from the face plate; and

a cutting tool for cutting the circular mounting hole opening in the building wall structure, the opening being sized to receive the circular side wall but not the face plate of the thermostat housing, the cutting tool including

a manual gripping handle coupled across a diameter of a cylindrically arranged plurality of cutting blades; and

a shaft extending along a center axis of the cylindrically arranged plurality of cutting blades, the shaft being partially hollow to receive wires when cutting the circular mounting hole opening.

2. The assembly of claim 1, wherein the face plate comprises one or more temperature sensors.

3. The assembly of claim 1, wherein after the moveable brace is moved to impinge the building wall structure, the face plate is configured to extend less than 1.5 centimeters from a front surface of the building wall structure.

4. The assembly of claim 1, wherein the face plate comprises a thermostat display.

5. The assembly of claim 1, wherein the brace actuator is configured for rotational movement to move the moveable brace linearly toward the face plate.

6. The assembly of claim 1, wherein the brace actuator is configured for linear movement to move the moveable brace linearly toward the face plate.

7. The assembly of claim 1, further comprising a removable cover plate configured to couple to a front surface of the face plate to cover an opening where the brace actuator is accessible through the face plate.

8. The assembly of claim 1, wherein the brace actuator comprises a screw.

9. The assembly of claim 1, the cutting tool further comprising

the shaft extends from within the plurality of cutting blades to a point beyond a front plane of the plurality of cutting blades;

wherein the plurality of cutting blades are configured to cut the circular mounting hole opening in the wall structure when the one or more cutting blades are engaged with the wall structure and a manual rotational force is applied in a direction of the cutting blades and the wall structure.

10. A method of installing a recessed thermostat assembly in a wall structure comprising:

cutting a circular mounting hole through the wall structure with a cutting tool by manually rotating the cutting tool and manually applying pressure against the cutting tool;

placing a thermostat assembly comprising at least one face plate and at least one side wall extending behind the face plate at an installed position with respect to the circular mounting hole in the wall structure, the installed position being where the face plate is against a first side of the wall structure and the at least one side wall extends into the wall structure;

actuating a brace actuator to linearly move a moveable brace into an engaged position with respect to the wall structure;

impinging at least a portion of the wall structure between the movable brace and a rear surface of the face plate;

coupling the thermostat assembly to the wall structure by locking the moveable brace in place against the wall structure after the wall structure is impinged;

threading thermostat wires extending from a wire hole in the wall structure into the cutting tool; and

placing a cutting tool guide in the wire hole around the thermostat wires.

11. The method of claim 10, further comprising:

engaging a front surface of the wall structure with the cutting tool, the cutting tool comprising a plurality of cutting blades arranged in a circle around the cutting tool guide with the cutting tool guide at the center of the circle; and

cutting the mounting hole through the wall structure with the cutting tool by continuing manual rotation and pressure.

12. The method of claim 11, wherein threading the thermostat wires into the cutting tool comprises threading the thermostat wires through the guide.

13. The method of claim 11, wherein placing the cutting tool guide in the wire hole around the thermostat wires further comprises positioning the guide within the hole with the thermostat wires extending through the guide, the guide comprising a plurality of different diameters, wherein the guide is inserted into the wire hole so that a guide portion having a diameter closest to but not greater than a diameter of the hole is positioned within the wire hole.

14. The method of claim 10, further comprising coupling a thermostat unit into an opening of the thermostat assembly and covering at least a portion of the thermostat unit with a cover plate that covers the opening to the thermostat assembly except for the portion of the thermostat unit.

15. A method of installing a recessed thermostat assembly in a wall structure comprising:

cutting a circular mounting hole through the wall structure with a cutting tool by manually rotating the cutting tool and manually applying pressure against the cutting tool;

placing a thermostat assembly comprising at least one face plate and at least one side wall extending behind the face plate at an installed position with respect to the circular mounting hole in the wall structure, the installed position being where the face plate is against a first side of the wall structure and the at least one side wall extends into the wall structure;

actuating a brace actuator to move a moveable brace into an engaged position with respect to the wall structure;

impinging at least a portion of the wall structure between the movable brace and a rear surface of the face plate;

coupling the thermostat assembly to the wall structure by locking the moveable brace in place against the wall structure after the wall structure is impinged;

threading thermostat wires extending from a wire hole in the wall structure into the cutting tool;

placing a cutting tool guide in the wire hole around the thermostat wires;

engaging a front surface of the wall structure with the cutting tool, the cutting tool comprising a plurality of cutting blades arranged in a circle around the cutting tool guide with the cutting tool guide at the center of the circle; and

cutting the mounting hole through the wall structure with the cutting tool by continuing manual rotation and pressure.

16. The method of claim 15, wherein threading the thermostat wires into the cutting tool comprises threading the thermostat wires through the guide.

17. The method of claim 15, wherein placing the cutting tool guide in the wire hole around the thermostat wires further comprises positioning the guide within the hole with the thermostat wires extending through the guide, the guide comprising a plurality of different diameters, wherein the guide is inserted into the wire hole so that a guide portion having a diameter closest to but not greater than a diameter of the hole is positioned within the wire hole.