Note: Descriptions are shown in the official language in which they were submitted.
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A PRE-FORMED INSERT BODY
FIELD OF THE INVENTION
[0001] The present invention relates to a component which can be
affixed to a
panel or affixed into a rebate of a panel, the component providing for a
structural support
for an item to be located within an aperture of said panel, or relates to an
insert for
altering the shape or size of an existing aperture through a panel, more
particularly,
though not solely, to a pre-form to be used as an insert into an existing
aperture through
a building panel.
BACKGROUND TO THE INVENTION
[0002] Various solutions have been proposed for reducing the size of
an aperture
through a panel, such as a ceiling or wall panel. In particular, problems
exist where for
example an existing aperture of a certain size has been made to accommodate,
say a
lighting fixture or a conduit to pass through the panel, but then that fixture
or conduit is
to be replaced with a smaller size which no longer needs the existing aperture
size.
[0003] Indeed, where the aperture size for the replacement fixture or
conduit or
any other such device extending through an aperture is smaller than the
existing
aperture, there becomes a problem as to how to adequately reduce the aperture
whilst
also ameliorating the gap between the existing aperture side wall and the size
of the
device to extending through the panel.
[0004] Typically, an existing aperture may be in-filled by using a
piece or pieces of
the same (or different) panel material. However, the jointed region between
such in-fill
materials and the panel itself may be weak or may weaken or fail over time.
For
example, where there is an existing circular aperture through a ceiling panel
and that
existing aperture is to be reduced in size, an annular ring of material may be
cut to be
inserted into the existing aperture to provide the new aperture size. The
joint between
the outer surface of the annular ring and the panel may be connected to each
other using
joint tapes and layers of concealing material (e.g. plaster). However, such a
solution still
presents problems as the joint region may fail or weaken, leading to problems
of cracked
concealing material (plaster) or other finishing materials (e.g. paints).
[0005] In this specification where reference has been made to patent
specifications, other external documents, or other sources of information,
this is
generally for the purpose of providing a context for discussing the features
of the
invention. Unless specifically stated otherwise, reference to such external
documents is
not to be construed as an admission that such documents, or such sources of
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information, in any jurisdiction, are prior art, or form part of the common
general
knowledge in the art.
[0006] Further aspects and advantages of the present invention will
become
apparent from the ensuing description which is given by way of example only.
SUMMARY OF THE INVENTION
[0007] It may therefore be an object of the present invention to
provide for an
insert component to be affixed to a panel to provide for a support structure
about an
aperture through said panel and/or which will go at least some way towards
addressing
the foregoing problems or which will at least provide the public with a useful
choice. Such
an insert is configured to receive or locate an item, such as a light fitting
or fixture, or
another item as may be described in this specification. It will be appreciated
other items
may be supported by the insert component as disclosed in this specification
and need not
be limited to those items which are specifically disclosed herein.
[0008] It may also be an object of the present invention to provide
for an insert
component capable of altering the shape and/or size of an existing aperture
through a
panel and/or which will go at least some way towards addressing the foregoing
problems
or which will at least provide the public with a useful choice.
[0009] In a first aspect there is provided an insert component to be
affixed to a
panel, said insert component comprising:
a body, the body including a first face and a second face, the body defining
at
least one opening extending between the first face and the second face, said
at least one
opening positioned within a perimeter of the body,
a flange portion extending substantially radially outwardly from one or each
of
said at least one opening, and
at least one first rim provided upon said first face and substantially about a
perimeter of each said opening, and at least one second rim provided upon said
first face
and substantially about the perimeter of each said opening, wherein said first
rim is
located outwardly of said second rim relative to said perimeter of each said
opening,
and wherein each of said first rim and said second rim are spaced from each
other
to define a channel region.
[0010] Each of said first rim and said second rim may be projections
extending
upwardly or away from said first face.
[0011] Each of said first rim and said second rim may be provided as
projections
upstanding from said first face.
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[0012] The first rim may be of a first rim height relative to a first
face surface of
said flange portion, and said second rim may be of a second rim height
relative to a first
face surface of said flange portion.
[0013] The first rim height may be substantially equal to or less
than said second
rim height.
[0014] The second rim height may be substantially equal to or greater
than said
first rim height.
[0015] The first rim height may be less than said second rim height.
[0016] A height of the first rim may be about lmm, or about 2mm, or
about
3mm, or about 4mm, or about 5mm, or about 6mm, or about 7mm, or about 8mm, or
about 9mm, or about 10mm, or may be less than about 10mm, or less than about
8mm,
or less than about 6mm, or less than about 4mm, or less than about 2mm, as
measured
from said first face of said body.
[0017] A height of the second rim may be about 2mm, or about 3mm, or
about
4mm, or about 5mm, or about 6mm, or about 7mm, or about 8mm, or about 9mm, or
about 10mm, or about llmm, or about 12mm, or may be less than about 12mm, or
less
than about 10mm, or less than about 8mm, or less than about 6mm, or less than
about
4mm, or less than about 2mm, as measured from said first face of said body.
[0018] The channel region may have a floor or base defining a channel
region
depth, said floor or base being of a level, or providing for floor or base
sections of a level,
which may be one or more of:
- a level substantially equal to said first surface of said flange portion,
- a level substantially lower than said first surface of said flange
portion,
- a level substantially higher than said first surface of said flange
portion.
[0019] The channel may be of a pre-determined width, said width defined
between facing side walls of each of said first rim and said second rim.
[0020] Said width may be sufficient to accommodate or receive a
(curable)
material.
[0021] The channel may be of a width that is greater than about 1mm,
or greater
than about 2mm, or greater than about 3mm, or greater than about 4mm, or
greater
than about 5mm, or greater than about 10mm, or greater than about 15mm, or may
be
about 2mm, or may be about 3mm, or may be about 4mm, or may be about 5mm, or
may be about 6mm, or may be about 8mm, or may be about 10mm, or may be less
than
10mm.
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[0022] The material may be a filler material (such as, but not
limited to, one or
more of: a plaster-type or render-type material, such as a material comprising
of
gypsum, lime or cement material, or is a material capable of being decorated
or may be
a material which can be finished, e.g. can be sanded to a finished surface,
for a
subsequent application of a decorative material, such as paint).
[0023] One or more of said at least one opening may further comprises
of a ledge,
said ledge providing a support surface extending substantially inwardly toward
a centre
of said opening.
[0024] The support surface may be a surface facing the same direction
as said
first face of said body.
[0025] The support surface may be a substantially planar surface.
[0026] The support surface may provide a surface upon which an item
is seatable.
[0027] The item may be a light fixture or fitting, or may be a smoke
alarm or
smoke detector or other fittings or fixtures.
[0028] One or more projections may be provided upon said second face of
said
body.
[0029] The projections upon said second face of said body may extend
a pre-
determined height or distance away from said second face.
[0030] The projections upon said second face may be provided to, in-
use, space
said body, via said second face, away from a surface upon which said second
face is to
be located.
[0031] The projections upon said second face may be provided to, in-
use, provide
a gap or a space between said second face and a surface upon which said second
face is
to be located.
[0032] The space or gap may provide a void into which a (optionally
curable)
material can be in-filled.
[0033] The one or more projections may be provided upon said second
face of
said body are distributed about said second face.
[0034] The one or more projections may be provided upon said second
face of
said body are distributed substantially evenly or equidistantly from each
other and about
said second face.
[0035] There may be six projections provided upon said second face of
said body.
[0036] The projections upon the second face may be of a pre-
determined height
or extend a distance away from the second face of about 0.5mm, or about 1mm,
or may
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be less than about 5mm, or less than about 4mm, or less than about 3mm, or
less than
about 2mm, or less than about 1mm, or less than about 0.5mm.
[0037] The flange may extend substantially about a part, or parts, or
substantially
an entirety, of said perimeter of said body.
[0038] The flange may extend as two opposing sides of said body (i.e. there
are
cut-off or straight side portions).
[0039] The flange may comprise one or more apertures, said apertures
extending
through said body.
[0040] The apertures may provide for a void through said body.
[0041] The apertures may be distributed about said flange.
[0042] The second face of said body may be a substantially planar
surface.
[0043] The second face of said body may be substantially planar,
apart from one
or more projections provided upon said second face of said body.
[0044] The body may be substantially circular, oval or of a
rectilinear perimeter
shape.
[0045] One or more of said at least one opening(s) may be
substantially circular,
oval or of a rectilinear perimeter shape.
[0046] The ledge may be substantially circular, oval or of a
rectilinear perimeter
shape.
[0047] A diameter of an inner perimeter of said second rim may be about
25mm
to about 104mm, or may be about 76mm, or may be about 86mm, or about 102mm, or
about 103mm, or about 104mm, or about 105mm, or about 106mm, or may be about
160mm, or may be about 200mm, or may be greater than about 10mm, or greater
than
about 20mm, or greater than about 25mm, or greater than about 30mm, or greater
than
about 35mm, or greater than about 40mm, or greater than about 50mm, or greater
than
about 85nnnn, or greater than about 100mm, or greater than about 105mm, or
greater
than about 125mm, or greater than about 150mm, or greater than about 175mm, or
greater than about 200mm, or greater than about 300mm, or greater than about
400mm.
[0048] The flange may be detachable or attachable or integral with said
body.
[0049] The first rim or said second rim, or both, may be detachable
or attachable
or with said body.
[0050] The ledge may be detachable or attachable or integral with
said body.
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[0051] The projections provided upon said second face of said body
may
detachable or attachable or integral with said body.
[0052] A separate component piece, such as a plate-type component
piece, may
be provided for seating upon the ledge.
[0053] The separate component piece may be provided as a plate-type
component
piece comprising of one or more apertures.
[0054] The separate component piece may be provided as a plug or cap
for the
insert component.
[0055] The separate component piece is substantially planar and of a
substantially
constant thickness.
[0056] The thickness of the separate component piece may be
sufficient so as to
align or be substantially matched with the second rim
[0057] The second rim may be of about a 2mm height, the first rim may
be of
about a 1nnnn height.
[0058] The separate component piece may be of about a 2mm thickness.
[0059] In a second aspect there is provided a structure formed in-
situ with a
panel, wherein an insert as defined in the first aspect or according to any
preceding
statement is affixed to a face of a panel.
[0060] A rebate is formed in said face of said panel, said rebate
being of a depth
to receive said insert, such that an end of said second rim is substantially
level or aligned
with said face of said panel, or an intended level of a finished or decorated
surface of said
panel.
[0061] It is further contemplated that where a light fitting or
fixture is described,
said light fitting may be substituted with any other fitting or component to
be installed
into a panel, such as, speakers, furniture, ducts, piping, components of alarm
or safety
systems (e.g., smoke detectors, gas detectors, infrared motion detectors) or
any other
outlet, utility or appliance.
[0062] It is further contemplated that any such fittings or
components or systems
to be installed may be retrofitted with suitable adaptors for installing into
a body or
assembly as described in any one of the preceding aspects or embodiments.
[0063] It is further contemplated that an assembly may comprise the
body as
described herein, and in particular with reference to any one or more of the
preceding
aspects or embodiments.
[0064] The invention described herein provides for at least two
separate rims,
being of the same or different height projections of the first face of the
body, where at
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least the first rim provides for a first reference height and the second rim
provides for a
second reference height. The reference heights being made with reference to
the first
face of the body or with reference to a face of a panel into which the insert
is to be
affixed or received.
[0065] In certain embodiments, the first rim is of a lower or smaller
height or size
then the second rim. In this manner, where for example a (curable) material
such as a
plaster is to be applied over the insert (for example to affixed of
mechanically engage the
insert with the panel to which it is to be affixed), a first application of a
material can be
made upon the insert, and an amount of material can be applied such that the
material is
applied to a thickness to align with the first rim. A second or subsequent
layer of material
may then be applied or coated, and this may be to a thickness to align with
the second
rim.
[0066] It will be appreciated the body of this invention may also be
utilised for use
in altering or reducing or amending the shape or dimension of other aspects of
an
aperture or opening through a panel.
[0067] In a third aspect there is provided an insert component to be
affixed to a
panel, said insert component comprising:
a body, the body including a first face and a second face, the body defining
at
least one opening extending between the first face and the second face, said
at least one
opening positioned within a perimeter of the body,
a flange portion extending substantially radially outwardly from one or each
of said
at least one opening, and
wherein at least a portion at the perimeter of the body is adjustable and/or
adaptable toward and/or away from the at least one opening.
[0068] The perimeter is moveable, preferably radially, so as to provide a
biasing
means for retaining the body in a rebate formed in the face of a panel, the
rebate being
of a depth to receive said insert.
[0069] In a particular form the rebate is formed in a ceiling
structure and the at
least one opening is adapted to receive a lighting fixture or the like ceiling
fixture such as
a sensor. In a preferred form the rebate is sized so as to receive the insert
with minimal
clearance such that the adjustable perimeter is adjustable/adaptable to engage
a side of
the rebate.
[0070] A suitable retention means for adjusting the perimeter may be
by way of
at least one resilient element located at the perimeter of the body, adapted
to provide an
outward bias to retain the body of the insert in a rebate. When in a retained
state a user
can apply a (curable) material such as a plaster over the insert. The
retention means can
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alternatively be termed a biasing element, perimeter expander, spring-biased
member or
any combination of these terms.
[0071] The resilient element may include an outward projection beyond
the main
perimeter. The projection may be of bevelled/tapered or spike form to engage
into a
surface of the rebate, in use.
[0072] The insert of the third aspect may incorporate and be combined
with any
or all additional features described above in relation to the first or second
aspect of the
invention. For example, the insert of the invention may further include
projections or
bumps on the rebate-facing face of the body so as to provide a spacing
function of the
body from the rebate inner surface and allow flow of adhesive and/or curable
material
such as plaster. In a fourth aspect there is provided an insert component to
be affixed to
a panel, said insert component comprising:
a body, the body including a first face and a second face, the body defining
at
least one opening extending between the first face and the second face, said
at least one
opening positioned within a perimeter of the body,
a flange portion located substantially radially outwardly from one or each of
said
at least one opening,
at least one rim provided upon said first face and substantially about a
perimeter
of each said opening, and
wherein said flange portion has a relatively greater wall thickness in a
region
adjacent to or at said rim, and is of a relatively reduced wall thickness in a
region
adjacent to or at said perimeter of said body.
[0073] At least one channel region may be provided in said first face
and
substantially about the perimeter of each said opening, said channel region
located
outwardly of said rim relative to said perimeter of each said opening.
[0074] The rim may be a projection extending upwardly or in a
direction away
from said first face and said second face.
[0075] The rim may be provided as a projection upstanding from said
first face.
[0076] The channel may be provided as a recess in said first face.
[0077] The channel may be located between the rim and said flange portion.
[0078] The rim may form a first channel wall of said channel.
[0079] A height of said first channel wall may be substantially equal
to or greater
than a second channel wall, and the second channel wall may be located
outwardly of
said first channel wall relative to said perimeter of each said opening.
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[0080] A height of the rim may be about 2mm, or about 3mm, or about
4mm, or
about 5mm, or about 6mm, or about 7mm, or about 8mm, or about 9mm, or about
10mm, or about 11mm, or about 12mm, or may be less than about 12mm, or less
than
about 10mm, or less than about 8mm, or less than about 6mm, or less than about
4mm,
or less than about 2mm, as measured from said first face of said body.
[0081] The channel region may have a floor or base defining a channel
region
depth, said floor or base being of a level, or providing for floor or base
sections of a level
substantially lower than said first face of said body and/or said flange
portion.
[0082] A depth of the channel may be about 1mm, or about 2mm, or
about 3mm,
or about 4mm, or about 5mm, or about 6mm, or about 7mm, or about 8mm, or about
9mm, or about 10mm, or may be less than about 10mm, or less than about 8mm, or
less than about 6mm, or less than about 4mm, or less than about 2mm, as
measured
from said first face of said body.
[0083] The channel may be of a pre-determined width, said width
defined
between said first channel wall and said second channel wall.
[0084] The width and/or said depth of said channel may be sufficient
to
accommodate or receive a (curable) material.
[0085] The width of the channel may be greater than about 1mm, or
greater than
about 2mm, or greater than about 3mm, or greater than about 4mm, or greater
than
about 5mm, or greater than about 10mm, or greater than about 15mm, or is about
2mm, or is about 3mm, or is about 4mm, or is about 5mm, or is about 6mm, or is
about
8mm, or is about 10mm, or is less than 10mm.
[0086] The material may be a filler material (such as, but not
limited to, one or
more of: a plaster-type or render-type material, such as a material comprising
of
gypsum, lime or cement material, or is a material capable of being decorated
or may be
a material which can be finished, e.g. can be sanded to a finished surface,
for a
subsequent application of a decorative material, such as paint).
[0087] One or more of said at least one opening may further comprise
of a ledge,
said ledge providing a support surface extending substantially inwardly toward
a centre
of said opening.
[0088] The support surface may be a surface facing the same direction
as said
first face of said body.
[0089] The support surface may be a substantially planar surface.
[0090] The support surface may comprise a channel or recess.
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[0091] The support surface of said ledge may be recessed from said
rim, or may
be of a reduced height relative to said rim.
[0092] The support surface may provide a surface upon which an item
is seatable.
[0093] The item may be one of: a light fixture or fitting, a smoke or
fire alarm or
detector, a sprinkler, an audio speaker, a ceiling mounted sensor, or other
fittings or
fixtures or devices.
[0094] The second face may comprise an inner portion and an outer
portion.
[0095] The outer portion may substantially correspond with said
flange portion,
and the inner portion may substantially correspond with said channel and said
rim.
[0096] The inner portion may be a raised or stepped region, raised or
stepped in a
direction to accommodate said channel.
[0097] A sidewall may define a step between said outer portion and
said inner
portion, and may be provided as a guide for locating said body into an
aperture of a
panel.
[0098] The outer portion may be substantially planar.
[0099] The outer portion comprises of an adhesive, projection or
fastener, and
may be adhered or affixed to a surface of a panel in use.
[0100] The outer portion may comprise one or more projections, the
one or more
projections being of a bevelled, tapered and/or of a spiked form.
[0101] The one or more projections may extend in a direction away from said
second face, or in a direction toward a surface of a panel to which said
insert is to be
affixed.
[0102] The one or more projections may provide for a mechanical
engagement or
attachment with the panel.
[0103] The one or more projections may be provided as an array about the
second face of said outer portion.
[0104] The flange portion may have a relatively greater wall
thickness in the
region adjacent to or at said channel, and may be of a relatively reduced wall
thickness
in a region adjacent to or at said perimeter of said body.
[0105] The flange portion may be of a wall thickness of about 0.5mm in a
region
adjacent to or at said perimeter of said body.
[0106] The flange portion may be of a wall thickness of about 1mm in
a region
adjacent to or at said channel.
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[0107] The flange portion may be substantially tapered in a reducing
wall
thickness, said wall thickness reducing in a direction as said flange portion
extends
substantially radially outwardly from said channel.
[0108] The first face may comprise said rim defining a first
projected height, said
flange portion at or substantially adjacent to said channel defining a second
projected
height, and said flange portion at or substantially adjacent to said perimeter
defining a
third projected height.
[0109] The rim may define a first projected height of said first
face, said flange
portion at or substantially adjacent to said channel may define a second
projected height
of said first face, and said flange portion at or substantially adjacent to
said perimeter
may define a third projected height of said first face.
[0110] The third projected height may be less than said second
projected height.
[0111] The third projected height may be less than said first
projected height.
[0112] The second projected height may be less than said first
projected height.
[0113] The third projected height may be less than said second projected
height,
and said second projected height may be less than said first projected height.
[0114] The flange portion may slope from said first projected height
to said third
projected height.
[0115] An outer edge of said flange portion may define said perimeter
of said
body.
[0116] The first face of said outer edge may comprise a chamfered
edge portion.
[0117] The first face may further comprise said support surface of
said ledge
defining a fourth projected height.
[0118] The fourth projected height may be less than said first
projected height, or
matches the height of the first projected height.
[0119] The flange portion may extend substantially radially outwardly
of said
channel.
[0120] The flange portion may extend substantially about a part, or
parts, or
substantially an entirety, of said perimeter of said body.
[0121] The flange portion may extend as two opposing sides of said body
(i.e. is
cut-off sides), or wherein two opposing sides of said flange portion are
substantially
parallel.
[0122] The flange portion may comprise one or more apertures, said
apertures
extending through said body.
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[0123] The apertures may provide for a void through said body.
[0124] The apertures may be distributed about said flange portion.
[0125] The channel may comprise one or more channel apertures, and
said
apertures may extend through said body.
[0126] The channel apertures may provide for a void through said body.
[0127] The channel apertures may be distributed about said channel.
[0128] The channel may comprise one or more ribs.
[0129] The one or more ribs may extend across said channel.
[0130] The one or more ribs may be strengthening members.
[0131] The one or more ribs may provide for a strengthening structure
between a
wall of said rim and a wall of said flange portion.
[0132] The one or more ribs may extend substantially across said
channel or said
floor of said channel, or between sidewalls of said channel.
[0133] The one or more ribs may be distributed about said channel.
[0134] The one or more ribs may be of a height below the first face, or
said one or
more ribs may be provided of a height recessed from said first face, or of
said flange
portion.
[0135] The body may be substantially circular, oval or of a
rectilinear perimeter
shape.
[0136] One or more of said at least one opening(s) may be substantially
circular,
oval or of a rectilinear perimeter shape.
[0137] The ledge may be substantially circular, oval or of a
rectilinear perimeter
shape.
[0138] A diameter of an inner perimeter of said rim may be about 25mm
to about
104mm, or is about 76mm, or about 8 6mm, or about 102mm, or about 103mm, or
about
104nnnn, or about 105nnm, or about 106mm, or may be about 160nnnn, or may be
about
200mm, or is greater than about 10mm, or greater than about 20mm, or greater
than
about 25mm, or greater than about 30mm, or greater than about 35mm, or greater
than
about 40mm, or greater than about 50mm, or greater than about 85mm, or greater
than
about 100mm, or greater than about 105mm, or greater than about 125mm, or
greater
than about 150mm, or greater than about 17 5mm, or greater than about 200mm,
or
greater than about 300mm, or greater than about 400mm.
[0139] The flange may be detachable or attachable or integral with
said body.
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[0140] The rim or the channel, or both, may be detachable or
attachable or
integral with said body.
[0141] The ledge may be detachable or attachable or integral with
said body.
[0142] A separate component piece, such as a plate-type component
piece, may
be provided for seating upon the ledge.
[0143] The separate component piece may be provided as a plate-type
component
piece comprising of one or more apertures.
[0144] The separate component piece may be provided as a plug or cap
for the
insert component.
[0145] The separate component piece may be substantially planar and of a
substantially constant thickness.
[0146] The insert as defined in any of the first, second, third,
fourth, or fifth
aspects may be affixed to a face of a panel.
[0147] A rebate may be formed in said face of said panel, said rebate
being of a
depth to receive said insert, such that an end of said rim is substantially
level or aligned
with said face of said panel, or an intended level of a finished or decorated
surface of said
panel.
[0148] A structure may be formed in-situ with a panel, and said
insert as defined
in any of the first, second, third, fourth, or fifth aspects may be affixed to
a face of the
panel, and a rebate may be formed in said face of said panel and sized so as
to receive
the insert such that the at least a portion at the perimeter of the body is
configured to
extend to engage a side of the rebate and retain the insert therewithin the
rebate.
[0149] The insert of the fourth aspect may incorporate and be
combined with any
or all additional features described above in relation to the first or second
or third aspect,
or with any or all additional features described below in relation to the
fifth aspect of the
invention. For example, the insert of the invention may further include
projections or
bumps on the rebate-facing face of the body so as to provide a spacing
function of the
body from the rebate inner surface and allow flow of adhesive and/or curable
material
such as plaster. Additionally, the insert may comprise one or more resilient
elements.
[0150] In a fifth aspect there is provided an insert component to be
affixed to a
panel, said insert component comprising:
[0151] a body, the body including a first face and a second
face, the body
defining at least one opening extending between the first face and the second
face, said
at least one opening positioned within a perimeter of the body,
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[0152] a flange portion located substantially radially outwardly
from one or
each of said at least one opening,
at least one rim provided upon said first face and substantially about a
perimeter
of each said opening, and
at least one channel region provided in said first face and substantially
about the
perimeter of each said opening, said channel region located outwardly of said
rim relative
to said perimeter of each said opening.
[0153] The rim may be a projection extending upwardly or in a
direction away
from said first face and said second face.
[0154] The rim may be provided as a projection upstanding from said first
face.
[0155] The channel may be provided as a recess in said first face.
[0156] The channel may be located between the rim and said flange
portion.
[0157] The rim may form a first channel wall of said channel.
[0158] A height of said first channel wall may be substantially equal
to or greater
than a second channel wall, and the second channel wall may be located
outwardly of
said first channel wall relative to said perimeter of each said opening.
[0159] A height of the rim may be about 2mm, or about 3mm, or about
4mm, or
about 5mm, or about 6mm, or about 7mm, or about 8mm, or about 9mm, or about
10mm, or about 11mm, or about 12mm, or may be less than about 12mm, or less
than
about 10mm, or less than about 8mm, or less than about 6mm, or less than about
4mm,
or less than about 2mm, as measured from said first face of said body.
[0160] The channel region may have a floor or base defining a channel
region
depth, said floor or base being of a level, or providing for floor or base
sections of a level
substantially lower than said first face of said body and/or said flange
portion.
[0161] A depth of the channel may be about 1mm, or about 2mm, or about 3mm,
or about 4nnnn, or about 5nnnn, or about 6nnnn, or about 7mm, or about 8nnnn,
or about
9mm, or about 10mm, or may be less than about 10mm, or less than about 8mm, or
less than about 6mm, or less than about 4mm, or less than about 2mm, as
measured
from said first face of said body.
[0162] The channel may be of a pre-determined width, said width defined
between said first channel wall and said second channel wall.
[0163] The width and/or said depth of said channel may be sufficient
to
accommodate or receive a (curable) material.
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[0164] The width of the channel may be greater than about 1mm, or
greater than
about 2mm, or greater than about 3mm, or greater than about 4mm, or greater
than
about 5mm, or greater than about 10mm, or greater than about 15mm, or is about
2mm, or is about 3mm, or is about 4mm, or is about 5mm, or is about 6mm, or is
about
8mm, or is about 10mm, or is less than 10mm.
[0165] The material may be a filler material (such as, but not
limited to, one or
more of: a plaster-type or render-type material, such as a material comprising
of
gypsum, lime or cement material, or is a material capable of being decorated
or may be
a material which can be finished, e.g. can be sanded to a finished surface,
for a
subsequent application of a decorative material, such as paint).
[0166] One or more of said at least one opening may further comprise
of a ledge,
said ledge providing a support surface extending substantially inwardly toward
a centre
of said opening.
[0167] The support surface may be a surface facing the same direction
as said
first face of said body.
[0168] The support surface may be a substantially planar surface.
[0169] The support surface may comprise a channel or recess.
[0170] The support surface of said ledge may be recessed from said
rim, or may
be of a reduced height relative to said rim.
[0171] The support surface may provide a surface upon which an item is
seatable.
[0172] The item may be one of: a light fixture or fitting, a smoke or
fire alarm or
detector, a sprinkler, an audio speaker, a ceiling mounted sensor, or other
fittings or
fixtures or devices.
[0173] The second face may comprise an inner portion and an outer
portion.
[0174] The outer portion may substantially correspond with said flange
portion,
and the inner portion may substantially correspond with said channel and said
rim.
[0175] The inner portion may be a raised or stepped region, raised or
stepped in a
direction to accommodate said channel.
[0176] A sidewall may define a step between said outer portion and
said inner
portion, and may be provided as a guide for locating said body into an
aperture of a
panel.
[0177] The outer portion may be substantially planar.
[0178] The outer portion comprises of an adhesive, projection or
fastener, and
may be adhered or affixed to a surface of a panel in use.
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[0179] The outer portion may comprise one or more projections, the
one or more
projections being of a bevelled, tapered and/or of a spiked form.
[0180] The one or more projections may extend in a direction away
from said
second face, or in a direction toward a surface of a panel to which said
insert is to be
affixed.
[0181] The one or more projections may provide for a mechanical
engagement or
attachment with the panel.
[0182] The one or more projections may be provided as an array about
the
second face of said outer portion.
[0183] The flange portion may have a relatively greater wall thickness in
the
region adjacent to or at said channel, and may be of a relatively reduced wall
thickness
in a region adjacent to or at said perimeter of said body.
[0184] The flange portion may be of a wall thickness of about 0.5mm
in a region
adjacent to or at said perimeter of said body.
[0185] The flange portion may be of a wall thickness of about 1mm in a
region
adjacent to or at said channel.
[0186] The flange portion may be substantially tapered in a reducing
wall
thickness, said wall thickness reducing in a direction as said flange portion
extends
substantially radially outwardly from said channel.
[0187] The first face may comprise said rim defining a first projected
height, said
flange portion at or substantially adjacent to said channel defining a second
projected
height, and said flange portion at or substantially adjacent to said perimeter
defining a
third projected height.
[0188] The rim may define a first projected height of said first
face, said flange
portion at or substantially adjacent to said channel may define a second
projected height
of said first face, and said flange portion at or substantially adjacent to
said perimeter
may define a third projected height of said first face.
[0189] The third projected height may be less than said second
projected height.
[0190] The third projected height may be less than said first
projected height.
[0191] The second projected height may be less than said first projected
height.
[0192] The third projected height may be less than said second
projected height,
and said second projected height may be less than said first projected height.
[0193] The flange portion may slope from said first projected height
to said third
projected height.
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[0194] An outer edge of said flange portion may define said perimeter
of said
body.
[0195] The first face of said outer edge may comprise a chamfered
edge portion.
[0196] The first face may further comprise said support surface of
said ledge
.. defining a fourth projected height.
[0197] The fourth projected height may be less than said first
projected height, or
matches the height of the first projected height.
[0198] The flange portion may extend substantially radially outwardly
of said
channel.
[0199] The flange portion may extend substantially about a part, or parts,
or
substantially an entirety, of said perimeter of said body.
[0200] The flange portion may extend as two opposing sides of said
body (i.e. is
cut-off sides), or wherein two opposing sides of said flange portion are
substantially
parallel.
[0201] The flange portion may comprise one or more apertures, said
apertures
extending through said body.
[0202] The apertures may provide for a void through said body.
[0203] The apertures may be distributed about said flange portion.
[0204] The channel may comprise one or more channel apertures, and
said
apertures may extend through said body.
[0205] The channel apertures may provide for a void through said
body.
[0206] The channel apertures may be distributed about said channel.
[0207] The channel may comprise one or more ribs.
[0208] The one or more ribs may extend across said channel.
[0209] The one or more ribs may be strengthening members.
[0210] The one or more ribs may provide for a strengthening structure
between a
wall of said rim and a wall of said flange portion.
[0211] The one or more ribs may extend substantially across said
channel or said
floor of said channel, or between sidewalls of said channel.
[0212] The one or more ribs may be distributed about said channel.
[0213] The one or more ribs may be of a height below the first face,
or said one or
more ribs may be provided of a height recessed from said first face, or of
said flange
portion.
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[0214] The body may be substantially circular, oval or of a
rectilinear perimeter
shape.
[0215] One or more of said at least one opening(s) may be
substantially circular,
oval or of a rectilinear perimeter shape.
[0216] The ledge may be substantially circular, oval or of a rectilinear
perimeter
shape.
[0217] A diameter of an inner perimeter of said rim may be about 25mm
to about
104mm, or is about 76mm, or about 86mm, or about 102mm, or about 103mm, or
about
104mm, or about 105mm, or about 106mm, or may be about 160mm, or may be about
200nnnn, or is greater than about 10nnnn, or greater than about 20nnnn, or
greater than
about 25mm, or greater than about 30mm, or greater than about 35mm, or greater
than
about 40mm, or greater than about 50mm, or greater than about 85mm, or greater
than
about 100mm, or greater than about 105mm, or greater than about 125mm, or
greater
than about 150mm, or greater than about 175mm, or greater than about 200mm, or
greater than about 300mm, or greater than about 400mm.
[0218] The flange may be detachable or attachable or integral with
said body.
[0219] The rim or the channel, or both, may be detachable or
attachable or
integral with said body.
[0220] The ledge may be detachable or attachable or integral with
said body.
[0221] A separate component piece, such as a plate-type component piece,
may
be provided for seating upon the ledge.
[0222] The separate component piece may be provided as a plate-type
component
piece comprising of one or more apertures.
[0223] The separate component piece may be provided as a plug or cap
for the
insert component.
[0224] The separate component piece may be substantially planar and
of a
substantially constant thickness.
[0225] The insert as defined in any of the first, second, third,
fourth, or fifth
aspects may be affixed to a face of a panel.
[0226] A rebate may be formed in said face of said panel, said rebate being
of a
depth to receive said insert, such that an end of said rim is substantially
level or aligned
with said face of said panel, or an intended level of a finished or decorated
surface of said
panel.
[0227] A structure may be formed in-situ with a panel, and said
insert as defined
in any of the first, second, third, fourth, or fifth aspects may be affixed to
a face of the
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panel, and a rebate may be formed in said face of said panel and sized so as
to receive
the insert such that the at least a portion at the perimeter of the body is
configured to
extend to engage a side of the rebate and retain the insert therewithin the
rebate.
[0228] The insert of the fifth aspect may incorporate and be combined
with any or
all additional features described above in relation to the first or second or
third or fourth
aspect of the invention. For example, the insert of the invention may further
include
projections or bumps on the rebate-facing face of the body so as to provide a
spacing
function of the body from the rebate inner surface and allow flow of adhesive
and/or
curable material such as plaster. Additionally, the insert may comprise one or
more
resilient elements.
[0229] The term "comprising" as used in this specification means
"consisting at
least in part of". When interpreting each statement in this specification that
includes the
term "comprising", features other than that or those prefaced by the term may
also be
present. Related terms such as "comprise" and "comprises" are to be
interpreted in the
same manner.
[0230] This invention may also be said broadly to consist in the
parts, elements
and features referred to or indicated in the specification of the application,
individually or
collectively, and any or all combinations of any two or more said parts,
elements or
features, and where specific integers are mentioned herein which have known
equivalents in the art to which this invention relates, such known equivalents
are deemed
to be incorporated herein as if individually set forth.
[0231] The invention consists in the foregoing and also envisages
constructions of
which the following gives examples only.
BRIEF DESCRIPTION OF THE DRAWINGS
[0232] Preferred embodiments of the invention will be described by way of
example only and with reference to the drawings, in which:
[0233] Figure 1 illustrates a top perspective view of one embodiment
of an insert
component,
[0234] Figure 2 illustrates a bottom perspective view of one
embodiment of an
insert component,
[0235] Figure 3 illustrates a side or elevation view of one
embodiment of an insert
component,
[0236] Figure 4 illustrates a top or plan view of one embodiment of
an insert
component,
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[0237] Figure 5 illustrates a bottom view of one embodiment of an
insert
component,
[0238] Figure 6 illustrates a cross-sectional view (section AA as
shown in Figure 5)
through an embodiment of an insert component,
[0239] Figure 7 illustrates a section of an insert component according to
the
present invention illustrating how the insert component can be located into a
rebate of a
panel, and different layers of materials applied to affix the insert component
into place,
[0240] Figure 8 illustrates a separate component piece which may be
provided for
seating upon a ledge of an insert component, to provide for a plug-type
arrangement,
[0241] Figure 9 illustrates how a separate component piece of, for example
that of
Figure 8, may be received by an insert component,
[0242] Figure 10 illustrates a top perspective view of a second
embodiment of an
insert component,
[0243] Figure 11 illustrates a bottom perspective view of the second
embodiment
of insert component,
[0244] Figure 12 illustrates a side or elevation view of the second
embodiment of
insert component, and
[0245] Figure 13 illustrates a section of an insert component
according to the
second embodiment illustrating how the insert component can be located into a
rebate of
a panel, and different layers of materials applied to affix the insert
component into place,
[0246] Figure 14 illustrates a bottom perspective view of a third
embodiment of
an insert component,
[0247] Figure 15 illustrates a top perspective view of the third
embodiment of an
insert component,
[0248] Figure 16 illustrates a side or elevation view of the third
embodiment of an
insert component,
[0249] Figure 17 illustrates a bottom view of the third embodiment of
an insert
component,
[0250] Figure 18 illustrates a top view of the third embodiment of an
insert
component,
[0251] Figure 19 illustrates a cross-sectional view (section BB as
shown in Figure
17) through an insert component according to the third embodiment,
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[0252] Figure 20 illustrates a section of an insert component
according to the third
embodiment illustrating how the insert component can be located into a rebate
of a
panel, and different layers of materials applied to affix the insert component
into place,
[0253] Figure 21 illustrates a section of an insert component
according to a third
embodiment illustrating differences in height of an insert component first
face due to a
rim and a taper of a flange section,
[0254] Figure 22 illustrates a bottom view of the third embodiment of
an insert
component including projections on a flange portion, and
[0255] Figure 23 illustrates a side or elevation view of the third
embodiment of an
insert component including projections on a flange portion.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0256] This invention provides for an insert component 1, that can
provide for a
member in the form of a body 2, to which a fitting or fixture may be mounted
or seated
upon and supported. Such a member can provide for a particular structural
support for a
fitting or fixture to be supported thereon or thereto.
[0257] The insert component 1 can also provide for a particular or
pre-determined
(i.e. a pre-formed) dimensioned or shaped opening. Such an opening providing
for
receipt of a fitting or fixture. Such a particularly dimensioned or shaped
opening provided
by the insert component may facilitate the re-sizing or alteration in shape of
an existing
aperture in a panel, the insert component capable of receiving such a fitting
of fixture.
[0258] The insert component (as described herein) can be located or
positioned
into a rebate or recessed region of a panel, such that the insert component
can be
subsequently mechanically fixed into place, for example by application of one
or more
layers of material, such as a curable material like plaster or other curable
medium or
adhesives. In this manner, the insert component can be integrated into the
panel. The
insert component then provides a particular structure for assisting with such
an
integration and as a support for a fixture of fitting.
[0259] This invention also provides for a relatively uncomplicated
system for
reducing the geometry, such as shape or size of an existing aperture, whilst
as the same
.. time provides a platform upon which materials, such as concealing
compositions ¨ e.g.
plaster, paint or other fillers or finishes, may be applied to conceal the
joint region
between the insert component and the surrounding panel.
[0260] It will also be appreciated the present invention may be
utilised for
improving or strengthening the aperture or opening cut or made in a building
panel to
receive a fitting, such as a light fitting (or any other outlet or utility
requiring an aperture
through a building panel) or a wall socket (such as for electrical outlets or
indeed any
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other outlet requiring an aperture through a building panel). For example, the
existing
aperture or opening referred to here may be the aperture which is initially
cut or made in
a building panel to then receive a fitting or fixture.
[0261] The insert component of the invention facilitates an
improvement in the
.. strength of the building panel around an aperture or opening through the
panel and any
finishes made about the aperture so cut or made, and in this way can help to
minimise
possible "break-out" in which the materials used around the aperture or
opening are
compromised as to their structural integrity due to forces imposed upon them,
for
example by a light fitting imparting a force on a building panel about the
aperture.
"Break out" may result in cracking of plaster or paint or other unsightly
effects in
decorative finishes around the aperture.
[0262] The insert component can facilitate the alteration in the
shape or size of an
aperture or opening through a panel, for example a building panel such as a
ceiling or a
wall. The following description is provided as exemplary of the invention, and
is made
with reference to the accompanying drawings.
[0263] Accordingly, described below are particular details of one
embodiment of
an insert component.
[0264] In one embodiment there is provided an insert component 1 to
be affixed
to, for example, a panel (P, see figure 7). The insert component 1 comprises a
body 2.
.. The body 2 includes a first face 3 and a second face 4. The body 1 defines
at least one
opening 5 that extends between the first face 3 and the second face 4. The at
least one
opening 5 is positioned within a perimeter (such as an outer perimeter) of the
body 1. A
flange portion 6 extending substantially radially outwardly from one or each
of said at
least one opening 5. At least one first rim 7 is provided upon the first face
3 and
substantially about a perimeter of each opening 5. At least one second rim 8
is provided
upon the first face 3 and substantially about the perimeter of each opening 5.
The first
rim 7 is located outwardly of the second rim 8, relative to the perimeter of
each opening
5. Each of the first rim 7 and the second rim 8 are spaced from each other to
define a
channel region 9 therebetween.
[0265] While a single opening 5 is shown in the accompanying figures, it
will be
appreciated that the body 2 may be of any shape or size and could accommodate
any
number of openings, where one or more of those openings can each be provided
with the
first rim and the second rim with the channel region located between those
rims. In this
manner, the number of openings 5 in a body 2 may be customised according to
the
number of fittings or fixtures which are to be received by the insert
component 1.
[0266] As is for example shown in the figures, each of the first rim
7 and second
rim 8 may be of the form of projections which extend in a direction upwardly
or away
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from said first face 3 of the body 1. That is, the first and second rims are
provided as
projections upstanding from the first face 3.
[0267] The first rim 7 can be of a first rim height 7H relative to
the first face 3
surface of said flange portion 6, while the second rim 8 can be of a second
rim height 8H
relative to a first face 3 surface of the flange portion 6.
[0268] The first rim height 7H can be substantially equal to or less
than the
second rim height 8H. Expressed in an alternative manner, the second rim
height 8H can
be substantially equal to or greater than the first rim height 7H.
[0269] Depending on the situational use, the first rim height 7H may
be of a
height that is less than the second rim height 8H.
[0270] In one example, the height 7H of the first rim 7 may be about
1mm, as
measured from the first face 3 of the body 1 to the most distal tip or end of
the first rim
7. In various other embodiments, a height of the first rim may be about 1mm,
or about
2mm, or about 3mm, or about 4mm, or about 5mm, or about 6mm, or about 7mm, or
about 8mm, or about 9mm, or about 10mm, or may be less than about 10mm, or
less
than about 8mm, or less than about 6mm, or less than about 4mm, or less than
about
2mm, as measured from said first face of said body.
[0271] In another example, the height 8H of the second rim 8 may be
about
2mm, as measured from the first face 3 of the body 1 to the most distal tip or
end of the
second rim 7. In various other embodiments, a height of the second rim may be
about
2mm, or about 3mm, or about 4mm, or about 5mm, or about 6mm, or about 7mm, or
about 8mm, or about 9mm, or about 10mm, or about 11mm, or about 12mm, or may
be
less than about 12nnnn, or less than about 10mm, or less than about 8nnnn, or
less than
about 6mm, or less than about 4mm, or less than about 2mm, as measured from
said
first face of said body.
[0272] The channel region 9 has a floor or base which defines a
channel region
depth 9H. The floor or base of the channel region 9 is of a level, or provides
for a floor or
base sections of a level, which may be one or more of:
- a level that is substantially equal to the level of the first surface 3
or of the flange
portion 6,
- a level that is substantially lower than the level of the first surface 3
or of said flange
portion 6,
- a level substantially higher than the level of the first surface 3 or of
the flange portion
6.
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[0273] The channel may be configured to be provided with a continuous
floor or
base, or the floor or base may be of a discontinuous form (i.e. the floor or
base may
comprise of apertures).
[0274] The depth of the channel region is advantageously sufficient
so as to allow
for a depth or thickness of material to be applied and to in-fill the channel
region 9.
[0275] The channel may be of a width that is greater than about lmm,
or greater
than about 2mm, or greater than about 3mm, or greater than about 4mm, or
greater
than about 5mm, or greater than about 10mm, or greater than about 15mm, or may
be
about 2mm, or may be about 3mm, or may be about 4mm, or may be about 5mm, or
may be about 6mm, or may be about 8mm, or may be about 10mm, or may be less
than
10mm.
[0276] The depth and/or width of the channel region 9 can provide for
a region of
increased material, and accordingly can provide for a stronger bond or
stronger plaster
edge or edge of material which is joining the insert component 1 to the
surrounding
panel material.
[0277] The channel region 9 is of a pre-determined width. This width
can be
defined between the facing side walls of each of the first rim 7 and the
second rim 8.
[0278] The width of the channel region is sufficient so as to
accommodate or
receive a (curable) material.
[0279] The material may be a filler material, such as, but not limited to,
one or
more of: a plaster-type or render-type material, such as a material comprising
of
gypsum, lime or cement material, or is a material capable of being decorated
or may be
a material which can be finished, e.g. can be sanded to a finished surface,
for a
subsequent application of a decorative material, such as paint.
[0280] The insert component 1 can optionally also comprises of a ledge 10.
[0281] A ledge 10 can be provided for one or more, or each of, the at
least one
opening(s) 5 of in the body 2.
[0282] The ledge 10 can provide a support surface 11 that extends
substantially
inwardly toward a centre of the opening 5 to which the ledge 10 is provided.
That is, one
or more, or all, of the openings through the body 2 can be provided with a
ledge 10,
each such ledge providing its own support surface 11.
[0283] The support surface 11 allows for the seating or receipt
thereon of a fixture
or fitting or another item or device which is to be received within the
opening 5. The
ledge 10 with its support surface 11 provides a structure upon which the
fixture or fitting
or item or device can be received or seated thereon.
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[0284] The support surface 11 can be a surface of the ledge which
faces in
substantially the same direction as the first face 3 of the body 2. It will be
appreciated
that the support surface of the ledge may be another surface of the ledge 10,
and is not
limited necessarily to being the surface identified as item 11. For example, a
rear side
surface labelled as item 12 may be used as the support surface, but in that
case such a
surface 12 would face in a different direction.
[0285] The support surface (whether as a surface 11 or 12) can be a
substantially
planar or flat surface, although it will be appreciated that other formations
(not shown)
may be provided upon the surface (11 or 12) to facilitate a suitable seating
of a fixture or
fitting or item or device.
[0286] The support surface advantageously provides a surface or a
platform upon
which an item is received thereon or is seatable.
[0287] The fixture or fitting may be a light fixture or a light
fitting, or may be a
smoke alarm or smoke detector or other fittings or fixtures or devices.
[0288] The second face 4 of the body 2 can comprises one or more
projections 13.
[0289] The projections 13 provided on the second face 4 of the body 2
can extend
a pre-determined height or distance away from the second face 4.
[0290] The projections 13, in-use, allowing for a spacing of the
second face 4 and
therefore the body 2, away from a surface (e.g. a surface of a panel) upon
which the
second face is to be located. That is, the projections 13 provide or
facilitate a gap or a
space to be formed between the second face 4 and the surface upon which the
body is to
be located (e.g. panel surface onto which the insert component is to be
positioned or
located).
[0291] It is the space or gap formed by the projections 13 which mean
a void is
created between the body 2 and the surface to which the insert component is to
be
affixed into which a (optionally curable) material can be in-filled.
[0292] The one or more projections 13 can be distributed about the
second face 4.
The distribution may be in a manner so as to substantially evenly support or
space the
second face of the body 2 from the surface upon which the insert component is
to be
affixed. In various embodiments, the projections 13 may be distributed
substantially
evenly or equidistantly from each other and about the second face 4.
[0293] In one particular embodiment there may be six projections
provided upon
the second face of the body 2, although it will be appreciated that any number
of
projections may be provided.
[0294] The projections upon the second face may be of a pre-determined
height
or extend a distance away from the second face of about 0.5mm, or about 1mm,
or may
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be less than about 5mm, or less than about 4mm, or less than about 3mm, or
less than
about 2mm, or less than about 1mm, or less than about 0.5mm.
[0295] The flange portion 6 can extend substantially about a part, or
parts, or
substantially an entirety, of the perimeter, such as the outer perimeter, of
the body 2.
[0296] The flange portion may be of any size, shape or dimension suitable
for
providing a region which extends the surface area for affixation of the insert
component
1 to a surface.
[0297] Particularly where a curable medium or material (e.g. plaster)
is used for
affixation of the insert component 1 to a surface, an increase in surface area
of the insert
component may be advantageous for increasing or improving the surface area for
a
mechanical adhesion.
[0298] The flange portion 6 can be provided as two opposing sides of
said body
(i.e. there are cut-off or straight side portions).
[0299] The flange portion 6 can have one or more apertures 14, the
apertures 14
extending through the body 2. The apertures 14 can provide for voids through
the body
2.
[0300] The apertures 14 can be distributed about the flange portion.
[0301] The apertures 14 can be a series of similar sizes and shapes,
or may be
the same or may be differently sized and shaped.
[0302] The apertures 14 allow for a curable material or medium, when
applied to
the first face 3, to be pushed through the apertures 14 so as to fill and be
provided in
contact with a surface of a panel to which the insert component is being
affixed.
[0303] Where for example the projections 13 are provided, then the
apertures 14
also allow for the material or medium to be applied and be applied through to
fill in the
space or gap or void created by the projections 13 standing the second face 4
off of the
surface of a panel. This allows for greater amounts of material or medium to
be applied
and to be provided for improved mechanical adhesion or connection between the
surface
and the insert component.
[0304] Optionally, a sufficient amount or quantity of material or
medium can be
applied so as to encapsulate the insert component 1 and to retain the insert
component
in-situ.
[0305] The second face 4 of the body 2 may be provided as a
substantially planar
surface, apart from the optional one or more projections 13 which would
otherwise be
provided thereon.
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[0306] However, other formations (not shown) may be provided on the
second
face 4 to facilitate further stand-off of the body from a surface to which the
insert
component is to be affixed, or may comprise of yet other functional formations
which
facilitate improve or greater mechanical connection of the insert component 1
to a
surface of a panel.
[0307] It will be appreciated that the insert component 1 may be of
any shape or
dimension, but particularly preferably may be shapes which are substantially
circular,
oval or of a rectilinear perimeter shape.
[0308] It will be appreciated that the opening 5 may be of any shape
or
dimension, but particularly preferably may be shapes which may be
substantially circular,
oval or of a rectilinear perimeter shape.
[0309] It will be appreciated that the ledge 10 may be of any shape
or dimension,
but particularly preferably may be shapes which are substantially circular,
oval or of a
rectilinear perimeter shape, or are suitable shaped and dimensioned relative
to the shape
and dimension of an associated opening 5.
[0310] A diameter of an inner perimeter of said second rim may be
about 25mm
to about 104mm, or may be about 76mm, or may be about 86mm, or about 102mm, or
about 103mm, or about 104mm, or about 105mm, or about 106mm, or may be about
160mm, or may be about 200mm, or may be greater than about lOmm, or greater
than
about 20mm, or greater than about 25mm, or greater than about 30mm, or greater
than
about 35mm, or greater than about 40mm, or greater than about 50mm, or greater
than
about 85mm, or greater than about 100mm, or greater than about 105mm, or
greater
than about 125mm, or greater than about 150mm, or greater than about 175mm, or
greater than about 200mm, or greater than about 300mm, or greater than about
400mm. The diameter may be of any diameter, but the above diameters may have
particular application utility.
[0311] The flange portion 6 can be provided as a component which is
detachable
or attachable or that is integral with the body 2.
[0312] The first rim 7 or the second rim 8, or both first and second
rims, can be
provided as a component or as each separate components, which are separately
or in a
combined manner, detachable or attachable or with the body 2.
[0313] The ledge 10 can be provided as a component that is detachable
or
attachable or that is integral with the body 2.
[0314] The projections 13 can be provided as separate components, or
a
combined component, for provision upon the second face 4 of the body 2, that
is
detachable or attachable or that is integral with the body 2.
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[0315] As for example shown in Figure 8, a separate component piece
15 can be
provided. Such a component piece 15 may for example be in the form of a plate-
type
component piece. Such a separate component piece 15 may be provided for
seating upon
the ledge 10.
[0316] The separate component 15 piece may comprise one or more apertures
16, which are configured to allow for the ingress of a material or medium as
described
elsewhere herein.
[0317] The separate component piece 15 can be provided as a plug or
cap for the
insert component 1. In this way, the insert component 1 can be put into
position with
respect to a panel P. and then the component piece 15 can be separately
installed upon
the insert component 1. It will be appreciated that the component piece 15 may
be
provided with additional formations to facilitate an improved quality of
connection with
the insert component or with a material or medium which is to be applied
thereon.
[0318] In one embodiment, the separate component piece 15 is
substantially
planar and of a substantially constant thickness. The thickness of the
separate
component piece may be sufficient so as to align or be substantially matched
with the
second rim
[0319] In a particular example, the second rim may be of about a 2mm
height,
the first rim may be of about a lmm height. Optionally, where a component
piece 15 is
also used, then the separate component piece may be of about a 2mm thickness.
[0320] Figure 9 illustrates the assembly or relative positioning of
the component
piece 15 upon the ledge of the insert component 1.
[0321] As for example shown in Figure 7, an insert component 1 can be
positioned
into a rebated region R of a panel P. The insert component 1 can then be
mechanically
affixed in place, for example by application of one or more layers of material
or medium
M.
[0322] According to the above description, there is provided herein
for an insert
component 1. The insert component 1 has desirable utility in providing for a
structure to
assist with the support of a fixture or fitting or other item or device which
is to be
provided in a panel (such as a ceiling or wall).
[0323] In one preferred mode of installation, the insert component 1
is to be
positioned within a rebated region of a panel surface. The rebate being of
sufficient depth
to accommodate the insert component 1. The rebate can be of a depth such that
the tip
or distal end of the second rim 8 is substantially in-line with the surface of
the panel into
which the insert component 1 is to be received. That is, a rebate can be
formed in a face
of a panel, with the rebate being of a depth to receive said insert, such that
an end or tip
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or distal point of the second rim is substantially level or aligned with the
face of the
panel, or an intended level of a finished or decorated surface of the panel.
[0324] It is further contemplated that where a light fitting or
fixture is described,
said light fitting may be substituted with any other fitting or component to
be installed
into a panel, such as, speakers, furniture, ducts, piping, components of alarm
or safety
systems (e.g., smoke detectors, gas detectors, infrared motion detectors) or
any other
outlet, utility or appliance.
[0325] It is further contemplated that any such fittings or
components or systems
to be installed may be retrofitted with suitable adaptors for installing into
a body or
assembly as described in any one of the preceding aspects or embodiments.
[0326] It is further contemplated that an assembly may comprise the
body as
described herein, and in particular with reference to any one or more of the
preceding
aspects or embodiments.
[0327] The invention described herein provides for at least two
separate rims,
being of the same or different height projections of the first face of the
body, where at
least the first rim provides for a first reference height and the second rim
provides for a
second reference height. The reference heights being made with reference to
the first
face of the body or with reference to a face of a panel into which the insert
is to be
affixed or received.
[0328] In certain embodiments, the first rim is of a lower or smaller
height or size
then the second rim. In this manner, where for example a (curable) material
such as a
plaster is to be applied over the insert (for example to affixed of
mechanically engage the
insert with the panel to which it is to be affixed), a first application of a
material can be
made upon the insert, and an amount of material can be applied such that the
material is
applied to a thickness to align with the first rim. A second or subsequent
layer of material
may then be applied or coated, and this may be to a thickness to align with
the second
rim.
[0329] The insert component 1 can be formed in any manner. However
preferred
may be casting or moulding, such as injection moulding or extrusion moulding,
.. depending on the shape of the body 2 and the other features which may be
provided.
[0330] Various individual or combinations or compound materials may
be used to
form the insert component 1. The material to use will depend on the specific
application
or use.
[0331] Examples of materials comprise one or more of: polymers such
as PE, PP,
PET, metals such as stainless steel, aluminium, and fibrous plasters such as
compositions
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comprising gypsum, polymers, metals, compositions comprising fibrous
reinforcement,
including cementitious fibre reinforced materials, fibre-glass materials.
[0332] It will also be appreciated sections or parts or portions of
the insert
component 1 may be formed of a combination or materials.
[0333] Yet further, it may be desirable for the insert component 1 to
achieve
certain desired characteristics in terms of structural strength, fire or
chemical resistance
or ability to retard fire. For example, components or compounds may be
included in the
body or the body so formed to achieve: electrical conductivity, anti-static
properties,
electrically insulation, fire resistance or fire retarding capabilities, or
even fire self-
extinguishing properties.
[0334] Where reference in this specification is made to a "panel",
such a panel
may include building panels, such as ceiling panels or wall panels. In certain
typical
applications, panel may be a building panel of fibrous plaster comprising
gypsum.
[0335] As described above, material or medium or adhesive or other
bonding or
curable agents may be utilised to assist or provide for affixation or
connection or
engagement or inter-connection the insert component 1 and surfaces of the
panel. In
these situations, an adhesive may be pre-applied or provided upon the insert
component
1 (such as upon the second face 4). The adhesive or bonding agent may have a
removal
backing, such as a paper or sheet, which once removed exposes the adhesive or
bonding
agent for use.
[0336] In various embodiments, the adhesive or bonding agent may be
curable by
exposure to the surface which it is desired to come into contact with.
Alternatively,
another means may be used to facilitate curing ¨ such as heat source, for
example infra-
red, or another energy source, for example ultra-sound, to excite the adhesive
and set-
off the curing process.
[0337] The materials or mediums or other agents can be passively or
actively
activated to cure and adhere to the panel so as to secure the insert component
1 in
position.
[0338] A concealing step allows for application of a sufficient
amount of the one or
more materials as discussed above. Application of the material is performed by
a user
until the first or front face is made level with the face of the panel.
Decoration or
finishing materials can then be finally applied.
[0339] Sufficient amounts of material, such as plaster or similar
materials, can be
applied upon the insert component 1 and the building panel, then allowing the
material,
such as plaster to cure, and then polishing the material, such as sanding of
plaster or
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similar material, to achieve a finished surface, optionally with a further
final finishing
material, such as a paint, applied.
[0340] Various tapes, such as a jointing tape, may be optionally
applied about
joint regions between the front face and the first face of the panel, although
the present
.. invention may allow a user to wholly negate the use of such an additional
joint
concealing material.
[0341] Figures 10 to 13 illustrate an additional feature aspect for
the insert, being
a perimeter retention means to hold the insert in place in a rebate, however,
the features
as described above, alone or in combination, are interchangeable and
compatible with
the retention feature.
[0342] Referring to figure 10 there is provided an insert component
21 to be
affixed to, for example, a panel (P, see figure 13). The insert component 21
comprises a
body 22. The body 22 includes a first face 23 and a second face 24. The body
21 defines
at least one opening 25 that extends between the first face 23 and the second
face 24.
The at least one opening 25 is positioned within a perimeter 26 (such as an
outer
perimeter) of the body 21.
[0343] In the illustrated form the perimeter is comprised of radially
extending
fingers to provide a broken circumference, however, this is merely a one
possible form
(e.g. implemented for material saving measures and greater surface area in
contact with
.. a curing material/adhesive) that may be, instead, an unbroken circular
perimeter as
shown in figure 1.
[0344] As above, the opening 25 may include a rim structure, e.g.
first rim 27
provided upon the first face 23 and substantially about a perimeter of each
opening 25. A
second rim 28 may be provided upon the first face 23 and substantially about
the
perimeter of each opening 25, where the first rim 27 is located outwardly of
the second
rim 28, relative to the perimeter of each opening 25. Each of the first rim 27
and the
second rim 28 are spaced from each other to define a channel region 29
therebetween.
However, it is noteworthy that this feature is an independent aspect from the
general
concept of a perimeter retention means as will be hereinafter described.
[0345] To assist a user in holding the body 22 in place when inserted into
a
rebate, at least one perimeter retention means 30 is provided. In the
illustrated form
there are three such retention devices 30 spaced, preferably evenly, about the
perimeter
26. In the illustrated form the retention device/means is comprised of a
resilient member
31 spanning between radially extending fingers such that, when a mid-point is
.. depressed, it will flex inwardly (toward opening 25) and bounce back
outwardly (away
from opening 25).
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[0346] Resilient member 31 preferably includes a protrusion 32 at the
mid-point
such that outward bias is directed through the protrusion 32 and onto any
surface with
which it is contacted. In the preferred usage situation, the surface in
contact with
perimeter protrusion 32 will be the edge/side wall of a rebate into which the
body is
inserted. This is generally illustrated by Figure 13 where a tapered/sharp
edge 33 of
protrusion 32 may bite into rebate wall R. Once held in place by the outward
bias of one
or more retention devices 30 a user can apply material M across the exposed
first face 23
which will incorporate the body permanently into the panel/ceiling structure.
[0347] Alternative forms of biasing/resilient/retention device are
possible without
departing from the scope of the invention. For example, an outwardly biased
member
(31, 32) may be mounted from a spring-loaded structure to generally provide
the
function of expanding the perimeter into engagement with a rebate wall or a
sliding
(biased or otherwise moveable radially outwardly) member (e.g. a spike) may
extend
into engagement with the rebate wall R.
[0348] Any of the disclosed insert components, such as insert component 41
shown in Figures 14 to 23, can provide for a member in the form of a body 42,
to which
a fitting or fixture may be mounted to, or seated upon, and thereby supported.
Such a
member can be provided as a structural support for a fitting or fixture to be
supported
thereon or thereto.
[0349] The insert component 41 can also provide for a particular or pre-
determined (i.e. a pre-formed) dimensioned or shaped opening 45. Such an
opening 45
providing the aperture for receipt therein of a fitting or fixture. Such a
particularly
dimensioned or shaped opening 45 provided by the insert component may
facilitate the
re-sizing or alteration in shape of an existing aperture in a panel, the
insert component
capable of receiving such a fitting of fixture. For example, the removal of
traditional
incandescent or halogen type light fittings and replacement by smaller format
light
fittings (e.g. LED lights) creates an issue of an overly large sized hole in a
panel, with a
smaller format light fitting to be replaced into that large(r) hole. As a
consequence, a
device which is capable of being provided in-situ into an existing aperture,
yet which
provides for a smaller (new) aperture to receive the new (smaller format)
light fitting is
advantageous. Similarly, in cases where retro-fitting of light is not needed,
but instead in
new builds or for new apertures being cut into panels, a device which provides
for a
suitable functionality to improve structural performance and reduce risks of
break out in
a friable panel (e.g. a plaster-type panel which may become compromised as to
structural integrity about an aperture cut therein).
[0350] The insert component (as described herein) can be located or
positioned
into a rebate or recessed region of a panel, such that the insert component
can be
subsequently mechanically fixed into place, for example by application of one
or more
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layers of material, such as a curable material like plaster or other curable
medium or
adhesives, or an adhesive tape, double sided tape, or by the use of fixing
means or
fasteners. In this manner, the insert component can be integrated or become
more
integrated into the panel. The insert component can then provide a particular
structure
for assisting with such an integration and as a support for a fixture of
fitting.
[0351] For example, a contact or pressure sensitive adhesive may be
provided on
a second face of the insert (being the face which is to be put into contact
with the panel),
and may be revealed upon removal of a release or peel sheet. Alternatively, an
adhesive
may be provided which is heat cured or otherwise cures upon contact or
placement when
placed against the panel to which the insert is to be mounted or affixed.
[0352] This invention can also provide for a relatively uncomplicated
system for
reducing or altering the geometry, such as shape or size of an existing
aperture, whilst at
the same time provides a platform upon which materials, such as concealing
compositions ¨ e.g. plaster, paint or other fillers or finishes, may be
applied to conceal
.. the joint region between the insert component and the surrounding panel.
[0353] It will also be appreciated the present invention may be
utilised for
improving or strengthening the aperture or opening cut or made in a building
panel to
receive a fitting, such as a light fitting (or any other outlet or utility
requiring an aperture
through a building panel) or a wall socket (such as for electrical outlets or
indeed any
other outlet requiring an aperture through a building panel). For example, the
existing
aperture or opening referred to here may be the aperture which is initially
cut or made in
a building panel to then receive a fitting or fixture.
[0354] The insert component 41 of the invention may facilitate an
improvement in
the strength of the building panel around an aperture or opening through the
panel and
any finishes made about the aperture so cut or made, and in this way can help
to
minimise possible "break-out" in which the materials used around the aperture
or
opening are compromised as to their structural integrity due to forces imposed
upon
them, for example by a light fitting imparting a force on a building panel
about the
aperture. "Break out" may result in cracking of plaster or paint or other
unsightly effects
.. in decorative finishes around the aperture.
[0355] The insert component can facilitate the alteration in the
shape or size of an
aperture or opening through a panel, for example a building panel such as a
ceiling or a
wall.
[0356] The insert component 41 as described herein can advantageously
provide
for ease of installation to or on a panel. In an example, the insert 41 can be
temporarily
held in place with an adhesive, fastener, or tape, such as a double-sided
tape, a pin,
screw, or nail, or a projection (such as a spiked projection) formed on a
flange 47 or
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second face 44 of the insert, to mechanically engage with a panel. In such an
example, a
curable adhesive m, such as a plaster, can be applied to the insert 41 to more
permanently affix the insert, whilst the temporary attachment means can hold
the insert
in place during said curing.
[0357] In some examples, a second face 44 of the insert may comprise two
portions 51 and 52, with one portion 51 being a stepped or raised region. In
an example,
the stepped region may comprise a sidewall 51A arranged to align the insert 41
to an
aperture in a panel, and or retain the insert 41 in an aperture in a panel.
[0358] The insert 41 as described herein may provide for a panel
surface mounted
component which can be aligned with an aperture in a panel, whether the
aperture is a
pre-existing aperture (i.e. for resizing of an existing hole in a panel or
other retro-fitting
capabilities) or a new/fresh hole (i.e. for new builds, or new installations
of fixtures into
panels). The insert may also be used to fill an existing hole (i.e. for
removing a fixture
from a wall, and filling the existing hole).
[0359] The insert 41 as described herein may provide for a relatively low
profile,
and may include a tapered region from an outer perimeter 46 towards an inner
portion,
the insert being thinner in profile towards an outer perimeter 46. In such an
example, a
plaster applied to said insert can taper to provide a more gradual change in
surface on a
panel. This may result in a reduced bulge appearance of the insert when
installed in a
panel.
[0360] The insert as described herein may be provided with a rim,
such as rim 48
in Figure 15, configured to act as a wall or edge to contain or align an
adhesive material
applied to the insert. Additionally, the channel 49 may also provide for a
means to accept
adhesive applied to the insert. Alone or in combination, the rim 48 and/or
channel 49
may provide for a means of containing a curable adhesive applied to the
insert, and as a
guide when finishing the curable adhesive (for example, when sanding after
curing) to
provide a clean or neat appearance to an edge of the curable adhesive
surrounding the
aperture of the insert 41.
[0361] Figures 14 to 23 illustrate an example embodiment of an
insert. Figures 14
and 15 shown perspective views of a second face 44 and a first face 43 of the
insert 41.
The insert 41 of Figures 14 to 23 can be affixed to a panel, and comprises a
body 42, the
body comprising a first face 43 and a second face 44. The body 42 defines at
least one
opening 45 extending between the first face 43 and the second face 44, said at
least one
opening 45 positioned within a perimeter 46 of the body 42. A flange portion
47 is
located substantially radially outwardly from one or each of said at least one
opening 45.
At least one rim 48 is provided upon said first face and substantially about a
perimeter of
each said opening 45. At least one channel region 49 is provided in said first
face 43, and
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substantially about the perimeter of each said opening 45, said channel region
49 located
outwardly of said rim 48 relative to said perimeter of each said opening 45.
[0362] In an alternative embodiment, there is provided an insert
component 41 to
be affixed to a panel, said insert component comprising a body 42, the body 42
including
a first face 43 and a second face 44, and the body 42 defining at least one
opening 45
extending between the first face 43 and the second face 44, said at least one
opening 45
positioned within a perimeter 46 of the body 42. A flange portion 47 is
located
substantially radially outwardly from one or each of said at least one opening
45. At least
one rim 48 is provided upon said first face 43 and substantially about a
perimeter of each
said opening 45. The flange portion 47 has a relatively greater wall thickness
in a region
adjacent to or at said rim 48, and is of a relatively reduced wall thickness
in a region
adjacent to or at said perimeter 46 of said body 42.
[0363] As shown in Figures 16 and 19, the rim 48 may be a projection
extending
upwardly or in a direction away from said first face 43 and said second face
44, such that
the rim 48 may be provided as a projection upstanding from said first face 43.
[0364] A height of the rim 48 may be about 2mm, or about 3mm, or
about 4mm,
or about 5mm, or about 6mm, or about 7mm, or about 8mm, or about 9mm, or about
10mm, or about llmm, or about 12mm, or may be less than about 12mm, or less
than
about 10mm, or less than about 8mm, or less than about 6mm, or less than about
4mm,
or less than about 2mm, as measured from said first face 43 of said body 42.
[0365] As shown in Figure 19, the channel 49 may be provided as a
recess in said
first face 43, and may be located between the rim 48 and said flange portion
47. The rim
48 may form a first channel wall 49A of said channel. A height of said first
channel wall
49A may be substantially equal to or greater than a second channel wall 49B,
and the
second channel wall 49B may be located outwardly of said first channel wall
49A relative
to said perimeter of each said opening. The second channel wall 49B may be
located at
an inner edge of the flange 47.
[0366] The channel region 49 may have a floor or base 49C defining a
channel
region depth, said floor or base 49C being of a level, or providing for floor
or base
sections of a level substantially lower than said first face 43 of said body
42 or said
flange portion 47.
[0367] A depth of the channel 49 may be about 1mm, or about 2mm, or
about
3mm, or about 4mm, or about 5mm, or about 6mm, or about 7mm, or about 8mm, or
about 9mm, or about 10mm, or may be less than about 10mm, or less than about
8mm,
or less than about 6nnnn, or less than about 4nnnn, or less than about 2nnnn,
as measured
from said first face 43 of said body 42.
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[0368] The channel 49 may be of a pre-determined width, said width
defined
between said first channel wall 49A and said second channel wall 49B.
[0369] As shown in Figure 20, the width and/or said depth of said
channel 49 may
be sufficient to accommodate or receive a (curable) material M.
[0370] The width of the channel 49 may be greater than about 1mm, or
greater
than about 2mm, or greater than about 3mm, or greater than about 4mm, or
greater
than about 5mm, or greater than about 10mm, or greater than about 15mm, or is
about
2mm, or is about 3mm, or is about 4mm, or is about 5mm, or is about 6mm, or is
about
8mm, or is about 10mm, or is less than 10mm.
[0371] The material M may be a filler material (such as, but not limited
to, one or
more of: a plaster-type or render-type material, such as a material comprising
of
gypsum, lime or cement material, or is a material capable of being decorated
or may be
a material which can be finished, e.g. can be sanded to a finished surface,
for a
subsequent application of a decorative material, such as paint).
[0372] One or more of said at least one opening 45 may further comprise of
a
ledge 50, said ledge 50 providing a support surface extending substantially
inwardly
toward a centre of said opening 45. The support surface may be a surface
facing the
same direction as said first face 43 of said body 42. The support surface may
be a
substantially planar surface, or alternatively the support surface may
comprise a channel
or recess. The planar surface, channel, or recess may be provided to receive a
fitting or
fixture as described herein. Additionally, the channel or recess of the
support surface
may be provided to reduce material thickness during a forming process of the
insert. The
support surface of said ledge 50 may be recessed from said rim 48, or may be
of a
reduced height relative to said rim 48. The support surface may provide a
surface upon
which an item is seatable, such as a light fixture or fitting, or a smoke
alarm or smoke
detector, or speaker, or other fittings or fixtures or devices.
[0373] The second face 44 may comprise an inner portion 51 and an
outer portion
52. The outer portion 52 may substantially correspond with said flange portion
47, and
the inner portion 51 may substantially correspond with said channel 49 and
said rim 48.
[0374] The inner portion 51 may be a raised or stepped region, raised or
stepped
in a direction to accommodate said channel 49.
[0375] A sidewall 51A may define a step between said outer portion 52
and said
inner portion 51, and may be provided as a guide for locating said body into
an aperture
of a panel.
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[0376] The outer portion 52 may be substantially planar, or may
comprise one or
more projections, such as projections 53 in Figures 22 and 23, the one or more
projections being of a bevelled, tapered and/or of a spiked form.
[0377] As shown in Figure 20, the outer portion 52 may be adhered or
affixed to a
surface of a panel P. In one example embodiment, the one or more projections
53, as
shown in Figures 22 and 23, may extend in a direction away from said second
face 44, or
in a direction toward a surface of a panel to which said insert 41 is to be
affixed. The one
or more projections 53 may provide for a mechanical engagement or attachment
with the
panel, and may be provided as an array about the second face 44 of said outer
portion
52. The one or more projections 53 may provide for a temporary, or initial, or
additional
engagement with a panel, in combination with a curable material applied to the
insert to
further adhere the insert 41 to the panel. Whilst four projections 53 have
been illustrated
in Figure 22, it will be understood that any number of projections may be
spaced or
provided in arrays on the insert 41 to provide the described initial
engagement with a
panel.
[0378] As for example shown in Figure 20, an insert component 41 can
be
positioned partially into a rebated region R a panel P. The insert component
41 can then
be mechanically affixed in place, for example by application of one or more
layers of
material or medium M. In an example embodiment, a first layer of material M1
may be
applied, which may include using a sidewall of rim 48 as a tool guide. This
layer of
material may fill channel 49, which is partially recessed into the rebated
region R of panel
P. The apertures 49D of channel 49 may allow for excess of first material M1
to escape
the channel into the space behind the insert, which may avoid the formation of
air
pockets within the channel. This can also provide for a greater volume of
material M1 to
be applied and received by the insert to assist with a greater volume of the
material M1
which can ultimately be cured in place to connect with the insert.
[0379] The first material M1 may also provide for a first layer of
adhesion for
adhering the flange region 47 to the panel P, which may include material M1
passing
through flange apertures 47A to adhere onto a surface of panel P. The first
material M1
may adhere the insert 41 to the panel P, and may add strength to the panel
and/or insert
surrounding a fixture to be fitted. Put another way, the first material M1 may
bridge or
facilitate strengthening of the connection joint made between the insert 41
and the panel
P.
[0380] Desirably, providing a system for strengthening the joint made
between
the insert and the panel may provide for a system which is capable of
receiving larger or
heavier items, yet avoiding or minimising the risks of break out. That is, the
insert of the
present disclosure may provide for an increased load factor capability
relative to a
traditional re-sizing of a hole which does not use the insert of this
invention.
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[0381] A second or finishing layer of material M2 may also be applied
to the
insert, which may include using the face or top of rim 48 as a tool guide.
This may allow
the second or finishing material M2 to be applied substantially level with the
face of rim
48, whilst covering flange 47 and channel 49. Such a configuration may provide
for a
finished or finishable (e.g. by sanding and/or painting) surface.
[0382] In one preferred mode of installation, as shown in Figure 20,
the insert
component 41 is to be positioned within a rebated region R of a panel surface
P. The
rebate R being of sufficient depth to at least partially accommodate the
insert component
41, for example to accommodate the second portion of the second face 44. Put
another
way, the rebate R may be of a depth such that the second portion of the second
face 44
is substantially within the rebate, whilst the ledge 50 is substantially in-
line with the
surface of the panel into which the insert component 41 is to be received.
That is, a
rebate can be formed in a face of a panel, with the rebate being of a depth to
partially
receive said insert, such that the flange portion 47 rests on the surface of
the panel.
[0383] The flange portion 47 may have a relatively greater wall thickness
in the
region adjacent to or at said channel 49, and may be of a relatively reduced
wall
thickness in a region adjacent to or at said perimeter 46 of said body 42. In
an example,
the flange portion 47 may be of a wall thickness of about 0.5mm in a region
adjacent to
or at said perimeter 46 of said body 42, and the flange portion 47 may be of a
wall
thickness of about 1mm in a region adjacent to or at said channel 49. The
flange portion
47 may be substantially tapered in a reducing wall thickness, said wall
thickness reducing
in a direction as said flange portion 47 extends substantially radially
outwardly from said
channel 49. It will be understood that the abovementioned flange portion
thickness is
exemplary, and the invention should be considered to incorporate any suitable
flange
portion thickness producing a tapered, curved, and/or angled profile.
[0384] As shown in Figure 21, the first face 43 may comprise said rim
48 defining
a first projected height Hi, said flange portion 47 at or substantially
adjacent to said
channel 49 defining a second projected height H2, and said flange portion at
or
substantially adjacent to said perimeter 46 defining a third projected height
H3. Each of
said first H1, second H2 and third H3 projected heights may be in reference to
the
second face 44, or a side of the flange portion 47 on the second face 44,
which may be
substantially planar as illustrated in Figure 21.
[0385] Put another way, the rim 48 may define a first projected
height H1 of said
first face 43, said flange portion 47 at or substantially adjacent to said
channel 49 may
define a second projected height H2 of said first face 43, and said flange
portion 47 at or
substantially adjacent to said perimeter 46 may define a third projected
height H3 of said
first face 43.
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[0386] The third projected height H3 may be less than said second
projected
height H2, and the first projected height H1. Similarly, the second projected
height H2
may be less than said first projected height H1. This may result in a
configuration where
the flange portion 47 may slope from said second projected height H2 to said
third
projected height H3.
[0387] The first face 43 may further comprise said support surface of
said ledge
50 defining a fourth projected height (indicated as H4), and the fourth
projected height
may be the same, or advantageously may be less than said first projected
height, or
matches the height of the first projected height. In an example embodiment,
the support
surface of said ledge 50 may be at substantially the same height as the second
face 44,
or a side of the flange portion 47 on the second face 44. In such a
configuration, when
the insert is installed with the second face 44 (or the side of the flange
portion 47 on the
second face 44) substantially parallel and abutted to the panel surface, the
support
surface of the ledge 50 may be at substantially the same height and/or level
as the
surface of the panel P. Alternatively, the support surface of the ledge 50 may
be
positioned to as to be above or below the surface level of the panel surface
or of the
second face 44, or a side of the flange portion 47 on the second face 44. This
may
facilitate a fixture or fitting installed in the insert to be placed at a
level corresponding
with the panel surface P. or may be recessed from the panel surface or may
project
slightly beyond the panel surface as desired by aesthetics of installation.
[0388] The fourth projected height H4 may be a zero, or a positive or
a negative
height value with respect to the reference plane defined by the second face of
the flange
portion 47. That is, the support surface of the ledge 50 may be provided so as
to provide
for a greater height of recess relative to the projected height of the rim
(being the first
projected height) or may be of a smaller projected height, or may be of the
same
projected height as the first projected height H1 of the rim 48.
[0389] An outer edge of said flange portion 47 may define said
perimeter 46 of
said body 42, and the first face 43 of said outer edge may comprise a
chamfered edge
portion as illustrated in Figure 21.
[0390] The flange portion 47 may extend substantially radially outwardly of
said
channel 49, and may extend substantially about a part, or parts, or
substantially an
entirety, of said perimeter 46 of said body 42. The flange portion 47 may
extend
continuously radially outwardly of said channel 49, or alternatively the
flange portion 47
may extend as two opposing sides of said body 42 (i.e. is cut-off sides, as a
radially
discontinuous flange portion).
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[0391] The flange portion 47 may comprise one or more apertures 47A,
said
apertures 47A extending through said body 42. The apertures 47A may provide
for a void
through said body 42, and may be distributed about said flange portion 47.
[0392] The channel 49 may comprise one or more channel apertures 49D,
and
said apertures 49D may extend through said body 42. The channel apertures 49D
may
provide for a void through said body 42, and may be distributed about said
channel 49.
[0393] The channel 49 may comprise one or more ribs 49E, and the one
or more
ribs 49E may extend across said channel 49. The one or more ribs 49E may be
strengthening members, and may provide for a strengthening structure between a
wall of
said rim 48 (for example channel sidewall 49A) and a wall of said flange
portion 47 (for
example channel sidewall 49B). The one or more ribs 49E may extend
substantially
across said channel 49 or said floor of said channel 49, or between sidewalls
49A/B of
said channel 49. The one or more ribs 49E may be distributed about said
channel 49.
[0394] The one or more ribs 49E may be of a height below the first
face 43, or
said one or more ribs 49E may be provided of a height recessed from said first
face 43,
and/or of said flange portion 47. In an example, the ribs 49E are provided as
recessed
ribs so as to not protrude through a curable material that may be applied to
insert 41.
[0395] The body 42 may be substantially circular, oval or of a
rectilinear perimeter
shape. Additionally, one or more of said at least one opening(s) 45 in said
body 42 may
be substantially circular, oval or of a rectilinear perimeter shape, and the
ledge 50 may
be substantially circular, oval or of a rectilinear perimeter shape.
[0396] A diameter of an inner perimeter of said rim 48 may be about
25mm to
about 104nnnn, or is about 76nnnn, or about 86nnnn, or about 102nnnn, or about
103nnnn, or
about 104mm, or about 105mm, or about 106mm, or may be about 160mm, or may be
about 200mm, or is greater than about 10mm, or greater than about 20mm, or
greater
than about 25mm, or greater than about 30mm, or greater than about 35mm, or
greater
than about 40mm, or greater than about 50mm, or greater than about 85mm, or
greater
than about 100mm, or greater than about 105mm, or greater than about 125mm, or
greater than about 150mm, or greater than about 175mm, or greater than about
200mm, or greater than about 300mm, or greater than about 400mm.
[0397] The flange 47 may be detachable or attachable or integral with
said body
42. Additionally, the rim 48 or the channel 49, or both, may be detachable or
attachable
or integral with said body 42, and the ledge 50 may be detachable or
attachable or
integral with said body 42.
[0398] A separate component piece, such as a plate-type component piece as
described in relation to Figure 9, may be provided for seating upon the ledge
50. The
separate component piece may be provided as a plate-type component piece
comprising
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of one or more apertures. The separate component piece may be provided as a
plug or
cap for the insert component, and may be substantially planar and of a
substantially
constant thickness. The plate-type component piece may be provided to fill an
unwanted
hole in a panel, and may be arranged to receive a curable material as
described herein.
[0399] As described herein, the insert 41 as defined in any of the
embodiments
disclosed herein may be affixed to a face of a panel. A rebate may be formed
in said face
of said panel, said rebate being of a depth to receive said insert 41, such
that an end of
said rim 48 is substantially level or aligned with said face of said panel, or
an intended
level of a finished or decorated surface of said panel.
[0400] A structure may be formed in-situ with a panel, and said insert 41
as
defined in any of the embodiments disclosed herein may be affixed to a face of
the panel,
and a rebate may be formed in said face of said panel and sized so as to
receive the
insert such that the at least a portion at the perimeter of the body 42 is
configured to
extend to engage a side of the rebate and retain the insert therewithin the
rebate. For
example, the side wall 51A of the stepped region of the second face 44 may
substantially
engage with a side of the rebate, and the flange portion 47 may substantially
overlap a
face of the panel.
[0401] The insert as described above in relation to Figures 14 to 20
may be
combined with any or all additional features described above. For example, the
insert of
the invention may further include projections or bumps on the rebate-facing
face of the
body so as to provide a spacing function of the body from the rebate inner
surface and
allow flow of adhesive and/or curable material such as plaster. Additionally,
the insert
may comprise one or more resilient elements or members, such as resilient
member 31
in Figure 10, arranged on a perimeter 46 of the body 42, and/or the sidewall
51A of the
second face 44.
[0402] The foregoing description of the invention includes preferred
forms thereof.
Modifications may be made thereto without departing from the scope of the
invention.
