BACKGROUND

This disclosure relates to an over torque protection device. The device may be used on the head of a screw or bolt to prevent an over torque condition.

SUMMARY

In one aspect, an over torque prevention device includes a cap configured for attachment to and removal from a threaded fastening member. The cap has a first portion shaped to engage a head of the threaded fastening member and has a second portion with a surface feature shaped to receive a driver tool for applying a torque to rotate the cap and the threaded fastening member. The cap is formed of a first material and the threaded fastening member is formed of a second material. The first material has a lower shear strength than the second material. When the driver tool engages the surface feature of the cap and applies an increasing torque, the surface feature of the cap deforms at a torque limit value such that further application of torque is prevented.

Examples may include one or more of the following features:

The threaded fastening member may be a screw or a bolt.

The first material may be a plastic.

The first portion may include a hexagonal key configured to engage a hexagonal opening in the head of the threaded fastening member. The first portion may include extensions configured to enable a user to grasp the extensions to apply the torque to rotate the cap. The second portion may include a pair of parallel surfaces. The cap may include a third portion shaped to receive a removal tool to remove the cap from the threaded fastening member.

The driver tool may be a screwdriver wherein the surface feature is shaped to receive an end of the screwdriver. The driver tool may be a wrench and the surface feature may include planar surfaces circumferentially arranged around an outer edge of the cap and configured to receive the wrench. The driver tool may be a socket driver and the surface feature may include planar surfaces circumferentially arranged around an outer edge of the cap configured to receive the socket driver. The driver tool may include a hexagonal key and the surface feature may be a hexagonal opening shaped to receive the hexagonal key.

In accordance with another aspect, an over torque prevention device includes a cap configured for attachment to and removal from a threaded fastening member. The cap has a first portion shaped to engage a head of the threaded fastening member and a second portion with a surface feature shaped to receive a driver tool for applying a torque to rotate the cap and the threaded fastening member. The cap is formed of a first material and the threaded fastening member is formed of a second material. The first material has a lower shear strength than the second material. When the driver tool engages the surface feature of the cap and applies an increasing torque, the first portion deforms at a torque limit value such that application of torque to the head of the threaded fastening member is prevented.

Examples may include one or more of the following features:

The threaded fastening member may be a screw or a bolt.

The first material may be a plastic.

The first portion may include a hexagonal key configured to engage a hexagonal opening in the head of the threaded fastening member. The first portion may include extensions configured to enable a user to grasp the extensions to apply the torque to rotate the cap. The second portion may include a pair of parallel surfaces. The cap may include a third portion shaped to receive a removal tool to remove the cap from the threaded fastening member.

The driver tool may be a screwdriver wherein the surface feature is shaped to receive an end of the screwdriver. The driver tool may be a wrench and the surface feature may include planar surfaces circumferentially arranged around an outer edge of the cap and configured to receive the wrench. The driver tool may be a socket driver and the surface feature may include planar surfaces circumferentially arranged around an outer edge of the cap configured to receive the socket driver. The driver tool may include a hexagonal key and the surface feature may be a hexagonal opening shaped to receive the hexagonal key.

In accordance with yet another aspect, a fastening device includes a threaded fastening member formed of a first material and having a head. The fastening device also includes a cap formed of a second material and configured for attachment to and removal from the head of the fastening member. The cap has a first portion shaped to engage a head of the threaded fastening member and has a second portion with a surface feature shaped to receive a driver tool for applying a torque to rotate the cap and the threaded fastening member. The first material has a lower shear strength than the second material. When the driver tool engages the surface feature of the cap and applies an increasing torque, at least one of the first portion and the surface feature deforms at a torque limit value such that further application of torque is prevented.

Examples may include one or more of the following features:

The first material may be a plastic. The second material may be a metal.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and further advantages of examples of the present inventive concepts may be better understood by referring to the following description in conjunction with the accompanying drawings, in which like numerals indicate like structural elements and features in various figures. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of features and implementations.

FIG. 1A is an illustration of a ceiling speaker system with an enclosure and mounting devices.

FIG. IB is a bottom view of the ceiling speaker system of FIG. 1 A.

FIG. 2 shows a single mounting device in FIG. 1A as attached to a recessed portion of one side of the enclosure.

FIG. 3A, FIG. 3B and FIG. 3C show the bracket in FIG. 2 from a perspective view, front view and side view, respectively.

FIG. 4 shows a perspective view of the spring-loaded tab of FIG. 2.

FIG. 5 shows an exploded view of the spring-loaded tab of FIG. 2.

FIG. 6 is a cutaway view of a portion of the ceiling speaker system of FIG. 1A showing one mounting device in an installed configuration.

FIGS. 7A to 7D illustrate the orientation of the second tab portion of a spring-loaded tab at different times during a ceiling speaker system installation process.

FIGS. 8 A to 8C illustrate the orientation of the second tab portion of a spring-loaded tab at different times during a process for removing a ceiling speaker system from a ceiling.

FIGS. 9A and 9B show examples of screws that can be used as threaded members in the described mounting devices.

FIG. 10A and FIG. 10B show perspective front and back views, respectively, of an example of an over torque prevention device that can be used with the screw of FIG. 9A.

FIG. 11 A and FIG. 1 IB show perspective front and back views, respectively, of an example of an over torque prevention device that can be used with the screw of FIG. 9B.

DETAILED DESCRIPTION

Speakers are often surface mounted to various structures such as ceilings and walls. Various forms of anchor systems are employed to reliably secure the speakers to the mounting substrates. During installation, mounting screws can be over tightened, or over torqued. As a result, one or more components of the anchor system may be damaged. If one of the components is strengthened to prevent it from being damaged during an over torque event, the failure is typically transferred to another component of the anchor system. If all components are sufficiently strengthened, the mounting substrate can be damaged if a screw is over torqued. For example, ceiling tiles, plywood or other types of mounting substrates may be damaged.

Various examples described below relate to an over torque prevention device that can be attached to fastening members such as mounting screws to prevent them from being over torqued. These devices prevent damage to the anchor system and mounting substrate during installation.

In the various devices and systems described below, "bracket" refers to an object that can be attached to a wall and used to support or hold another object or structure. A "fastening member" is a device or component used to mechanically join or affix two or more objects to each other. A "cap" includes a lid or cover that can be attached to at least a portion of an object. A ceiling, as used herein, means the upper interior structure of a room or dwelling. A ceiling may be horizontal or may be inclined at an angle from a horizontal orientation.

FIG. 1A shows an example of a ceiling speaker system 10 that includes an enclosure 12 and four mounting devices (only two visible) used to mount the system 10 to a ceiling. Each device includes a spring-loaded tab 14, a bracket 16, a threaded rod 18 and a cap nut, or acorn nut, 20.

FIG. IB shows a bottom view of the system 10 with a rectangular grille 22 at the system base. For example, the grille 22 may be attached to a flange 24 via magnetic connectors on the flange 24 and/or on the top side of the grille 22. The grille 22 shields and protects internal system components while being substantially acoustically transparent to acoustic signals generated by the speaker system 10. It will be noted that the position and angular orientation of the spring-loaded tabs 14 along their threaded rods 18 in FIGS. 1A and IB are generally different although, as described below, once the speaker system 10 is installed in the ceiling, the position and angular orientation of the spring-loaded tabs 14 with respect to their threaded rods 18 are nominally the same.

FIG. 2 is a view of a single mounting device attached to a recessed portion of one side of the enclosure 12 with the spring-loaded tab 14 located near the bottom of the enclosure 12. The threaded rod 18 is substantially parallel to the adjacent side of the enclosure and has a head at one end configured to receive a driver tool, such as a screwdriver or socket driver, which enables an installer to rotate the rod 18. The cap nut 20 is attached to the opposite end of the threaded rod 18 and prevents the rod 18 from retracting or moving downward through the bracket 16 while allowing the rod 18 to rotate freely about its axis during installation and removal of the ceiling speaker system.

FIGS. 3A to 3C show the bracket 16 from a side view, front view and perspective view, respectively. The bracket 16 includes a first bracket portion 32 having openings 38 to engage or pass screws, bolts or rivets for securing the bracket 16 to the enclosure 12. The bracket 16 also includes a second bracket portion 34 extending substantially perpendicularly from the first bracket portion 32 at one end and includes a third bracket portion 36 at the bottom of the bracket 16. Two openings 40 are provided in the bracket 16. One of the openings 40 allows the threaded rod 18 to pass through a section 42 that extends between the bottom of the first bracket portion 32 and the top of the third bracket portion 36. The other opening 40 is in the second bracket portion 34 for use as a supplemental hang point.

FIG. 4 and FIG. 5 show a perspective view and an exploded view, respectively, of the spring-loaded tab 14. The tab 14 includes a first tab portion 50 having a generally cylindrical shape at its ends, a central region including a threaded passage 51 to engage the threaded rod 18, and a stop surface 52. The tab 14 further includes a second tab portion 54 that has an outer surface 56 and a ceiling clamp surface 57. In one example, the first and second tab portions 50 and 54 are made of a polymer such as acrylonitrile butadiene styrene (ABS) or other plastic. In alternative examples, the first and second tab portions 50 and 54 can be made of a different moldable material or a metal such as a die cast aluminum. A spring mechanism, such as the illustrated spring wire 58, engages the first and second tab portions 50 and 54. The second tab portion 54 is rotatable about an axis 60 that is substantially perpendicular to both the threaded passage 51 and the rod axis. A tab clamp 62 and screws 64 secure one end of the spring wire 58 to the second tab portion 54 while the opposite end is attached to the first tab portion 50. The spring wire 58 maintains the second tab portion 54 against the first tab portion 50, as shown in FIG. 4; however, with a force applied to the outer surface 56 that is sufficient to overcome the torsional force of the spring wire 58, the second tab portion 54 rotates downward about the axis 60.

FIG. 6 illustrates a cutaway view of a portion of the ceiling speaker system 10 showing one mounting device in an installed configuration. An edge portion of the ceiling (not shown) that is adjacent to the ceiling opening resides in the gap between the speaker system flange 24 and the ceiling contact surface 57 of the second tab portion 54. Prior to completion of installation, the gap is greater than the thickness of the ceiling; however, as the threaded rods 18 are rotated to cause the speaker system 10 to rise upward through the ceiling opening, the gap decreases until the gap thickness equals the ceiling thickness. Further rotation of the threaded rods 18 results in an increasing force that clamps the ceiling between the flange 24 and the ceiling contact surface 57.

The ceiling opening is sized to closely pass all but the flange 24 of the ceiling speaker system 10. More specifically, the length and width of the opening are slightly greater than the length and width of the enclosure 12 at its base so that all but the flange 24 of the speaker system 10 can freely pass through but not greater than the designed clamp range of the second tab portions 54 in their fully extended position (see FIGS. 7A and 7D). Conversely, the length and width of the ceiling opening are less than the length and width of the flange 24.

Reference is now made to FIG. 7A to 7D which depict the orientation of the second tab portion 54 of a spring-loaded tab during different times of a ceiling installation process. Prior to installation, each spring-loaded tab is in an angular position in which it has a maximum horizontal extension outward from near the base of the enclosure at an angle θι about axis 60 (into page, also see FIG. 4) and relative to a vertical direction. In one non-limiting numerical example, the angle 9L is approximately 30°. As the ceiling speaker system and enclosure pass through the opening in the ceiling 60, the outer surface 56 of each second tab portion 54 comes into contact with an edge 61 of the ceiling 60 at the opening. Further upward movement urges the second tab portion 54 to rotate relative to the axis 60 through a decreasing angle 02 as shown in FIG. 7B. Continued upward movement of the speaker system and enclosure cause the second tab portion 54 to continue to pivot inward toward the enclosure to a reduced angle θ ₃ about the axis 60 and to approach a vertical orientation as shown in FIG. 7C. In this manner the tabs reduce their outward extension so that they pass through the ceiling opening along with the speaker system and enclosure. Eventually, the tabs emerge past the top of the opening and the second tab portions 54 spring back outward to their initial "locked" position at an angle θι. At this time, an installer can release the ceiling speaker system so that it is temporarily supported by the ceiling contact surface 57 on each second tab portion 54 which is in contact with the top surface 66 of the ceiling 60 as shown in FIG. 7D. Thus the system does not fall back through the ceiling opening and does not require an installer for support. While conveniently held in place by the tabs, the installer rotates the threaded rods (e.g., screws) with a screwdriver or other driver tool, to further raise the ceiling speaker system and enclosure until the speaker system flange comes into contact with the bottom surface 68 of the ceiling 60. Further rotation of the threaded rods results in application of a clamping force applied between the flange and the ceiling contact surfaces 57 of the second tab portions 54.

Preferably, the spring-loaded tabs are positioned in advance of the installation process at a location along the length of their threaded rods to accommodate the particular ceiling thickness such that the installer needs only to make a small number of rotations of the threaded rods to bring the flange into contact with the ceiling bottom surface 68 and apply the desired clamping force. For example, for a 2.5 cm ceiling thickness, the spring-loaded tabs may be set at an initial position along the rods to provide a gap of approximately 3.0 cm between the ceiling contact surface 57 of the second tab portion 54 and the speaker system flange.

It may be desirable at a later time to remove, or "un-install," the ceiling speaker system from the ceiling. To remove the system, the threaded rods are rotated in an opposite direction to that used during the installation process. This causes the speaker system to lower through the ceiling opening while the each spring-loaded tab remains stationary relative to the ceiling in an angular position φ ₁ for maximum horizontal extension as shown in FIG. 8 A. During this time, the ceiling contact surface 57 of the second tab portion 54 remains in contact with the top surface 66 of the ceiling 60 but moves up the threaded rod. As the speaker system continues to pass downward through the ceiling opening, the third bracket portion 36 of each bracket engages the outer surface 56 of the second tab portion 54. Subsequent downward movement of the speaker system results in the third bracket portion 36 urging the second tab portion 54 toward a vertical orientation through a reduced angle φ ₂ , as shown in FIG. 8B, until the angular position is at a sufficiently small angle φ ₃ to allow the retracted spring- loaded tab to clear the edge of the ceiling opening as shown in FIG. 8C. With all four tabs sufficiently retracted, the removal of the speaker system from the ceiling can be completed.

While the examples described above include four mounting devices per ceiling speaker system, it will be recognized that in other ceiling mount configurations fewer or more mounting devices may be used with a speaker system. Moreover, it will be recognized that the mounting devices can be used to mount other types of objects to a ceiling and to allow for their convenient removal from the ceiling.

The threaded rod used in the in installation of the ceiling speaker system to a ceiling can be over tightened, or over torqued. As a result, one or more components (e.g., threaded rod, bracket and spring-loaded tabs) of the mounting devices may be damaged. If a component of the mounting device is strengthened to prevent it from being damage during an over torque event, the failure is typically transferred to another component of the mounting device. If all mounting device components are sufficiently strengthened, the mounting substrate can be damaged. For example, ceiling tiles, plywood or other types of mounting substrates used to support the speaker system may be damaged.

In some installations, installers use electrical drills which typically provide insufficient feedback to the installer to sense when the torque has increased to a desired torque level or a maximum acceptable torque level. Alternatively, an adjustable torque screwdriver may be used to achieve the desired clamping force for an installation; however, if the screwdriver maximum torque value is incorrectly set, the applied torque may be incorrect for the installation. For example, if the value is set too low, the ceiling speaker system may become loose with time and separate from the mounting substrate. In contrast, if the value is set too high, the mounting device or mounting substrate may be damaged during installation.

FIGS. 9A and 9B show examples of screws 70 and 80 that can be used as threaded members (e.g., elements 18 in FIG. 1) in the mounting devices described above or, more generally, as a threaded fastening member for applications in which two or more objects are fastened together. Referring also to FIG. 2, the screw 70 includes a head 72 and a threaded portion 74 to engage the threaded passage of the first tab portion of a spring-loaded tab. The head 72 has a flat surface with a "+" shaped recessed feature 76 configured to receive the tip of a Phillips® screwdriver. Similarly screw 80 has a head 82 and threaded portion 84. The head 80 has a flat surface with a hexagonal socket recessed feature 86 configured to receive a hexagonally-shaped tip of a driver tool such as a hex socket key. Both heads 72 and 82 have a hexagonal circumferential surface that includes six individual planar surfaces 78 and 88, respectively. In some implementations, the screw 70 or 80 can also be turned using a driver tool having a hexagonal socket that engages the planar surfaces 78 or 88, respectively.

Reference is also made to FIG. 10A and FIG. 10B which show perspective front and back views, respectively, of an example of an over torque prevention device 90 that can be used with the screw 70 of FIG. 9A. The device 90 is in the form of a cap having a first portion 92 shaped to engage the head 72 of the screw 70 and a second portion 94 having a surface feature 96 shaped to receive a driver tool for applying a torque to rotate both the cap 90 and screw 70. The cap 90 is formed of a material that has a lower shear strength than the screw material so that the screw has a greater torque bearing capacity. As used herein, shear strength is the strength of the material against the type of yield or structural failure in which the material or component fails in shear. In one example, the cap 90 is formed of a plastic or other polymer and the screw may be made of a metal such as stainless steel or steel.

Polymers have lower strength properties than a metal and therefore yield at lower shear values than metals. A polymer material may be selected for its yield characteristics and formed with an appropriate geometry so that the cap 90 yields at a predetermined torque.

The recessed region in the first portion 92 of the cap 90, as shown in FIG. 10B, is sized to closely receive the head 72 of the screw 70. The six "points" of the hexagonal

circumferential surface occupy the six gaps 98 in the first portion 92. The cap 90 can be pressed onto the head 72 to achieve a tight interference fit such that the cap 90 is firmly secured. The installer then inserts the tip of the driver tool into the surface feature 96 and rotates the tool, causing the screw 70 to similarly rotate. As resistance to rotation increases, the installer must provide increasing torque to rotate the screw 70. When the applied torque increases to a torque limit value, the cap 90 deforms to prevent further application of torque. By way of a non-limiting numerical example, the cap 90 deforms once the applied torque increases to a value in a range from about 1.1 N m (10 in. lb.) to about 1.7 N m (15 in. lb.). In one example, the surface feature 96 deforms, is stripped or "rounds out," when the torque limit value is reached. Thus the cap 90 is rendered unusable for the further application of torque. In an alternative example, the recessed region in the first portion 92 deforms so that the cap 90 no longer tightly grips the screw head 72. Thus the cap 90 acts as a mechanical fuse to prevent the application of excessive torque to the screw 70 and excessive force to any structure being clamped or fastened by the screw 70.

In some instances, it can be necessary remove the cap 90 after deformation and installation is substantially completed. For example, the presence of the caps 90 on the threaded rods 18 of FIGS. 1A and IB may interfere with mounting of the grille 22 to the ceiling speaker system 10. The illustrated cap 90 includes a third portion in the form of two parallel surfaces 100 shaped to receive a removal too to allow the cap 90 to be removed from the screw heads 72. For example, the surfaces 100 may be grasped by pliers and the cap 90 then pulled from the screw head 72. Advantageously, this also exposes the screw head 72 and allows for a driver tool to rotate the threaded rods 18 in the event that the speaker system is to be removed from the ceiling.

In an alternative example, the cap is shaped with two or more projections that allow a hand to act as the driver tool. An installer grasps the projections and turns the cap by hand to apply a torque that can reach the torque limit value. In one such implementation, the outer structure of the cap is shaped like a wing nut for easy manipulation.

Reference is now made to FIG. 11 A and FIG. 1 IB which show perspective front and back views, respectively, of an example of an over torque prevention device 1 10 that can be used with the screw 80 of FIG. 9B. The device 100 is in the form of a cap in which similar features to that of the cap 90 of FIGS. 10A and 10B are designated by similar reference numbers; however, the recessed region in the first portion 92 includes a hexagonal key extension 1 12 sized to closely fit the hexagonal socket recessed feature 86 in the screw head 82. When the installer applies torque that increases to a torque limit value, the cap 1 10 deforms to prevent further application of torque. For example, the surface feature 96 deforms or "rounds out" when the torque limit value is reached, as described above for FIGS. 10A and 10B. In an alternative example, the recessed portion in the first portion 92 deforms so that the cap 110 no longer tightly grips the screw head 82. For example, the six planar surfaces 114 of the hexagonal key extension 1 12 and/or the six planar surfaces 1 16 surrounding the recessed region may deform, or round out.

In various examples described above, the threaded fastener member is described as a screw. In alternative examples, the over torque prevention device can be attached to other types of fasteners, including bolts and hexagonal threaded nuts, having other types of fastener heads configured for use with different types of drivers. It will be recognized that the specific surfaces in the over torque prevention device may have other shapes, for example, to allow for their use with other types of fastener heads. In one example, the deformable surface feature is a circumferential arrangement of planar surfaces around an outer edge of the cap configured to receive a wrench or socket driver. Moreover, in light of the description provided above, it will be recognized that the specific materials, shapes, features and dimensions can vary and may be selected to achieve a desired torque limit value for particular applications.

A number of implementations have been described. Nevertheless, it will be understood that the foregoing description is intended to illustrate, and not to limit, the scope of the inventive concepts which are defined by the scope of the claims. Other examples are within the scope of the following claims.