Wall mountable device, method of manufacture, and wall mounting method

Abstract

A wall mountable device has a body of predetermined shape for forming a wall feature and a flat, peripheral flange of predetermined width projecting outwardly from the perimeter of the body. The body may be a light sconce or valance, niche, shelving unit, bas-relief, or other wall feature. The flange has a periphery of predetermined shape for mounting in a wall opening of corresponding shape and dimensions with the outer face of the flange flush with the surrounding wall surface, and the seam or joint between the flange and wall opening is finished such that the body appears to be molded integrally with the wall.

I claim:  
     
         1 . A wall mountable device, comprising: 
 a body of predetermined shape for forming a wall feature, the body having a perimeter and a flat, peripheral flange of predetermined width projecting outwardly from the perimeter of the body; and    the flange having periphery of generally rectangular shape for mounting in a wall opening of corresponding shape and dimensions, the flange having an outer face, whereby the flange can be recessed into the wall with the outer face of the flange flush with the surrounding wall surface, such that the body appears to be molded integrally with the wall.    
     
     
         2 . The device as claimed in  claim 1 , wherein the flange is of predetermined thickness equal to the thickness of the wall in which it is to be mounted.  
     
     
         3 . The device as claimed in  claim 1 , wherein the body comprises a light sconce of generally bowl-like shape having a recess with an upwardly facing opening for receiving a light fitting, the sconce having an inner flat wall and the flange projecting outwardly from the sconce and substantially co-planar with the inner flat wall of the sconce.  
     
     
         4 . The device as claimed in  claim 1 , wherein the body comprises a niche having an indent projecting inwardly in a first direction and an outer periphery, the flange projecting outwardly in a direction transverse to said first direction.  
     
     
         5 . The device as claimed in  claim 1 , wherein the body comprises a shelving unit having a plurality of shelves and a peripheral wall surrounding the shelves, the flange projecting outwardly from the peripheral wall in a direction perpendicular to the peripheral wall.  
     
     
         6 . The device as claimed in  claim 1 , wherein the body has a central opening and a recessed, flat rim surrounding the opening and recessed inwardly from the outer face of the flange for receiving a wall plate.  
     
     
         7 . The device as claimed in  claim 6 , including a cover plate seated on the flat, recessed rim and extending over the opening, the cover plate being releasably secured to the rim and having an outer face flush with the outer face of the flange.  
     
     
         8 . The device as claimed in  claim 1 , wherein the flange has a width of at least two inches around the entire perimeter of the body.  
     
     
         9 . The device as claimed in  claim 1 , wherein the body and flange are integrally molded.  
     
     
         10 . A method of mounting a device in a wall, comprising the steps of: 
 taking a wall mountable device having a shaped body with a flat, outwardly projecting peripheral flange having a perimeter of predetermined shape and dimensions;    cutting an opening of predetermined shape and dimensions matching the flange perimeter in a wall board for receiving the device;    placing the wall mountable device in the wall board opening with the perimeter of the flange in abutment with the edge of the opening and the outer surface of the flange flush with the surrounding wall surface; and    securing the flange in the wall opening.    
     
     
         11 . The method as claimed in  claim 7 , wherein the step of securing the flange in the wall opening comprises securing the flange to wall studs behind the opening.  
     
     
         12 . The method as claimed in  claim 7 , further comprising the steps of covering perimeter seams formed between the flange and edge of the wall opening with drywall tape, and coating the flange and adjacent wall surface with drywall mud.  
     
     
         13 . The method as claimed in  claim 9 , including the step of coating and texturing the wall mounted device to match the color and texture of the surrounding wall, whereby the device appears to be formed integrally with the wall.  
     
     
         14 . The method as claimed in  claim 7 , wherein the perimeter of the flange is of rectangular shape, and a matching rectangular opening is cut in the wall at a selected position.  
     
     
         15 . A method of manufacturing a device for flush mounting in a wall opening, comprising the steps of: 
 forming a model of the device comprising a body having a perimeter and a peripheral flat flange of predetermined width extending around the perimeter of the body, the model having an upper surface;    covering the model with a parting film;    applying a coating layer of clay of predetermined thickness over the parting film to cover the upper surface of the model and extend down over the peripheral edge of the flange;    pouring a shell of moldable material over the coating layer;    allowing the shell to harden;    removing the shell from the model and coating layer;    removing the clay coating layer from the model;    placing the shell over the model so that there is a cavity of thickness equal to that of the coating layer between the model and the shell;    forming a pour hole in the shell;    pouring a liquid mold material for forming a flexible liner through the pour hole to fill the cavity;    allowing the liquid mold material to cure to form a flexible liner;    removing the shell from the model and liner;    peeling the cured liner from the model;    inverting the shell and reinserting the liner into the shell; and    pouring a liquid cement material into the liner to form a device which is a duplicate of the model.    
     
     
         16 . The method as claimed in  claim 12 , wherein the body is a bowl shape having a cavity with an opening facing in a direction parallel to the plane of the flange, and including the additional steps of inserting a plug into the model cavity and supporting the plug to leave a gap between the inner surface of the cavity and the plug, prior to forming the shell over the model and plug, and, after forming the shell, pouring the liquid molding material to fill the gap between the model, plug and shell which is a negative of the desired device shape.  
     
     
         17 . The method as claimed in  claim 12 , wherein the liquid molding material is rubber.  
     
     
         18 . The method as claimed in  claim 13 , including the additional step of embedding legs in the shell before it hardens in order to support the inverted shell in a horizontal orientation.