AU2004203459B2 - A Component Installation System and Method of Use - Google Patents

Description

P/00/011 28/5/91 Regulation 3.2 AUSTRALIA Patents Act 1990 ORIGINAL COMPLETE SPECIFICATION STANDARD PATENT Name of Applicant: Holyoake Industries Limited Actual Inventor Scott Noel Holyoake Address for service is: WRAY & ASSOCIATES Level 4, The Quadrant 1 William Street Perth, WA 6000 Attorney code: WR Invention Title: "A Component Installation System And Method Of Use" The following statement is a full description of this invention, including the best method of performing it known to me: 1 A COMPONENT INSTALLATION SYSTEM AND METHOD OF USE TECHNICAL FIELD 5 This invention relates to the provision of a component installation system and a method of using such a system. Preferably, the present invention may be adapted to facilitate the installation of components into the interior walls, floor or ceiling of a structure. Reference throughout this specification will also be made to the components to be installed being air circulation or conditioning components, but 10 those skilled in the art should appreciate that other types of components may also be installed in conjunction with the present invention. BACKGROUND ART In many instances, there is a need to install numerous different types of components within the interior surface of a structure. For example, in building construction, air 15 circulation and conditioning, lighting, power and other utility based components need to be installed within wall, floors or ceilings of a building and in some instances, also need protrude out from the surfaces involved. The components installed need to function effectively and should not also detract from the aesthetic appeal or appearance of a finished building surface. This can be a difficult objective 20 to achieve in cases where the component is relatively large or weighty, as is the case with air circulation components. In a number of instances, grills, diffusers or ducting need to be anchored directly to the structural elements and supports of a wall, floor or ceiling to support the weight of the component. An existing approach used to install such components is to cut a hole in the exterior 25 cladding of a wall for example, hopefully in proximity to the structural elements or 2 supports used in the construction of the wall. In the case of installation of a component in a wall, a hole is usually cut in the exterior surface cladding of the wall in the vicinity of the studs and nogs of the timber framework of the wall. The component involved is then directly connected to the framework exposed, with an 5 edging flange being applied to the perimeter of the component to extend out and cover any gaps left between the perimeter of the hole cut and the main body of the component installed. Due to the inaccurate approach used to form the original cavity in the surface cladding, this exterior or perimeter flange needs to extend out from the component 10 over a reasonable distance to make up for any inaccuracies in the placement of the cavity formed. This large extending flange or ledge can be visually unappealing and detract from the aesthetic qualities of some forms of components. This approach can cause some timing difficulties with respect to when the final finish is applied to a wall or other form of surface. If the exterior finish of, for example, a 15 wall including a final coat of paint is applied prior to the cutting of the hole required, the installation of the component can cause damage to this exterior finish which will need to be touched up and repaired. Conversely, if the component is installed prior to the wall or surface being finished and painted, the component in turn will need to be masked and covered during painting and finishing of a wall or surface. This 20 creates further work and may also result in the surface or finish of the component being damaged when masking tape is removed, or if masking tape is not used there may be the need to remove paint splatter from the component. It would be of advantage to have a component installation system and/or method which addressed any or all of the above problems. A system or method which 25 allowed the accurate placement of components with respect to the surface cladding of a surface such as a wall, floor or ceiling would be of advantage. Furthermore, a 3 system or apparatus which eliminated or substantially reduced the size of any covering flange or edging ledge normally employed at the perimeter of a component to cover gaps between the body of the component and the edge of the exterior cladding of a surface would be of advantage. 5 All references, including any patents or patent applications cited in this specification are hereby incorporated by reference. No admission is made that any reference constitutes prior art. The discussion of these references states what their authors assert, and the applicants reserve the right to challenge the accuracy and pertinency of the cited documents. It will be clearly understood 10 that, although a number of prior art publications are referred to herein, this reference does not constitute an admission that any of these documents form part of the common general knowledge in the art, in New Zealand or in any other country. It is acknowledged that the term 'comprise' may, under varying jurisdictions, be 15 attributed with either an exclusive or an inclusive meaning. For the purpose of this specification, and unless otherwise noted, the term 'comprise' shall have an inclusive meaning - i.e. that it will be taken to mean an inclusion of not only the listed components it directly references, but also other non-specified components or elements. This rationale will also be used when the term 'comprised' or 20 'comprising' is used in relation to one or more steps in a method or process. This rationale will also be used when the term "include" and variations such as "includes" or "including" is used. The present invention seeks to address the foregoing problems or at least to provide the public with a useful choice. 25 Further aspects and advantages of the present invention will become apparent from the ensuing description which is given by way of example only. 30 4 DISCLOSURE OF INVENTION According to one aspect of the present invention there is provided a component installation system adapted to install a component substantially within a surface, said installation system including, 5 an outer frame adapted to connect the system to at least one structural element used to form the surface within which a component is to be installed, said outer frame defining at least one interface surface adapted to contact an exterior cladding applied to the surface, and an inner core which includes or is adapted to engage with the component to be 10 installed, said inner core being adapted to sit substantially within said outer frame and to be engaged with said outer frame. According to a further aspect of the present invention there is provided a method of installing a component within a surface, comprising, (i) attaching an outer frame to at least one structural element of a 15 surface, and (ii) applying an exterior cladding over said at least one structural element of the surface, said cladding being located in contact with at least one interface surface defined by said outer frame, and (iii) inserting and retaining an inner core within the outer frame, said inner 20 core including the component to be installed. According to a further aspect of the present invention there is provided a method of installing a component within a surface, comprising, (i) attaching an outer frame to at least one structural element of a surface, and 25 5 (ii) applying an exterior cladding over said at least one structural element of the surface, said cladding being located in contact with at least one interface surface defined by said outer frame, and (iii) inserting and retaining an inner core within the outer frame; and 5 (iv) engaging a component with the inner core to install the component substantially within the surface. The present invention is adapted to provide a system, method and apparatus for installing a component within a surface. Components to be installed may encompass a wide range of elements, all of which preferably are to be installed 10 permanently within the interior walls, floor or ceiling of a structure or building. Preferably the present invention may be used in the installation of air circulation or conditioning components within the interior surfaces of a structure. Air circulation or conditioning components can be relatively large and heavy, and as such, may require special installation systems and methods in some instances. 15 In a further preferred embodiment the present invention may be used to install components within a wall. A wall may be used to form the surface in which components are to be installed as required by a particular form or configuration the component involved. Reference throughout this specification will also be made to the present invention 20 being used to install air conditioning components within the interior walls of a structure or building. However, those skilled in the art should appreciate that other types of components may also be installed in conjunction with the present invention and reference to the above only throughout this specification should in no way be seen as limiting. Furthermore, those skilled in the art should also appreciate that 6 reference to the installation of components within the interior walls only of a structure should again and in no way be seen as limiting, as the present invention may also be adapted or used to install components into the ceiling or floor of a structure if required in other embodiments. 5 Preferably a wall within which a component is to be installed may include both structural elements and an exterior cladding. Structural elements can provide the wall or surface formed with strength and structural integrity, while the exterior cladding applied can give the wall an attractive, even and uniform finish. Structural elements can be capable of supporting the weight of a component to be installed. 10 The components employed to form a structural elements or the cladding will vary depending on the construction of the wall. For example, in some instances, timber or steel framing could be used as structural elements, while wooden panels or plaster board could be used to provide the exterior cladding. Reference throughout this specification will also be made to the wall in which a 15 component is to be installed including a wooden framework of studs and nogs as structural elements over which an exterior cladding of plaster board is applied. However, those skilled in the art should appreciate that other forms of wall construction may also employ the present invention if required and reference to the above only throughout this specification should in no way be seen as limiting. 20 Reference throughout this specification will also be made to a component being installed substantially within a surface, or preferably a wall. Those skilled in the art should appreciate that such components may in fact protrude slightly out from the exterior of a surface or wall in some instances or in other instances may be recessed slightly within, or lie flush with the surface if required. 25 Preferably the present invention may include an outer frame. This outer frame can 7 be adapted to be directly secured or connected to at least one of the structural elements of a wall and preferably to secure and support the weight of any component to be installed. The outer frame may preferably be inserted into a wall cavity between structural elements such as nogs and studs when timber 5 framing is used to form a wall. In such a preferred embodiment, the outer frame may be directly bolted, screwed, nailed or otherwise adhered or connected to the nogs and/or studs that it lies adjacent to, to in turn allow the structural elements of the wall to support the weight of any component installed. Preferably the outer frame may be adapted to define and include at least one 10 interface surface which in use can be placed in contact with an exterior cladding applied to the wall or surface involved. Preferably an interface surface is adapted to contact or engage with an edge of the exterior cladding applied to a wall so that the outer frame provided will fill any cavities or gaps in the exterior cladding provided for the component to be installed. Preferably the interface surface or 15 surfaces provided may define the perimeter of the frame and may also preferably follow the outline or profile of the component to be installed. For example, if in one instance the component to be installed has a substantially rectangular profile or perimeter, the frame may be formed with four interface surfaces which in turn define a rectangular form complementary to that of the component. 20 Preferably as discussed above, an interface surface formed by the outer frame may in use be placed in contact with the edges of the exterior cladding of a wall. Those skilled in the art should appreciate that reference to the term "in contact" may also encompass exterior cladding being placed in close proximity to the interface surface at some points, but not necessarily being fully in contact with 25 the interface surface at all points along its length. Furthermore, this term should also be understood to encompass the provision of corking, stopping or other forms of filing compound 30 8 dispersed between an interface surface and an edge of the exterior cladding material used to contact an interface surface with cladding, and to fill and cover any small gaps or inconsistencies between these components. Accordingly, a filling compound may be used to contact at least one interface surface with an 5 exterior cladding applied to the surface. Preferably the present invention may also include an inner core which is adapted to sit substantially within the outer frame. This inner core can be retained and engaged with the framing of the wall. Reference throughout this specification will also be made to the inner core being adapted to sit substantially within the outer 10 frame. Those skilled in the art should appreciate that this terminology should be understood to encompass the inner core also projecting slightly out above the upper surface of the outer frame if required. Preferably the inner core may be adapted to be retained or engaged with the outer frame to secure the inner core in place with respect to the wall or surface 15 the outer frame is connected to. In a preferred embodiment the inner core may be adapted to engage with the component to be installed. In such an embodiment the component involved may preferably be removably engaged with the inner core to in turn allow the component to be installed through the use of the outer frame discussed above. 20 Allowing the component involved to be added or removed from the inner core allows various different types of components with substantially the same shape to be used with a single inner core. Reference throughout this specification will also be made to the component involved being engaged with the inner core while still being able to be removed 25 from the inner core if required. However, those skilled in the art should appreciate that the inner core may also be formed integrally with, within or as part of the component to be 30 9 installed and reference to the above only throughout this specification should in no way be seen as limiting. In a further preferred embodiment, the present invention may include a frame connector used or adapted to engage or retain the inner core with respect to the 5 outer frame. Preferably such a frame connector may allow for the releasable engagement or connection of these two components together thereby allowing the inner core to be secured in place but also removed for maintenance or repair if required. In a further preferred embodiment a frame connector may be formed by at least 10 one spring clip. Spring clips can use the resilient properties of some of the materials to deform and subsequently releasably engage the outer frame with the inner core. For example, in one instance, such a frame connector may be formed from a spring clip attached to one side of the inner core, with the core having an 15 extending leg which can engage with a series of ratchet teeth or at least one projection formed in an adjacent section of the outer frame. Thus, a frame connector way include at least one extending leg. Those skilled in the art should appreciate that many other types of frame connectors may also be employed in conjunction with the present invention if required. 20 Preferably, the outer frame includes at least one projection adapted to engage with a frame connector. The present invention may be used to quickly and also accurately install a component within a wall or other surface, without necessarily requiring a large covering flange to be provided at the perimeter of the component when installed. 25 Initially, the outer frame employed may be fixed to the structural elements of a wall or other surface prior to an exterior cladding being applied to same. The exterior cladding required for the wall may then be fixed into a place and engaged directly into contact with the interface surfaces of the outer frame, thereby accurately positioning the edges of the outer frame into contact with the edges of 30 any cavity formed in the wall for installation purposes. 1n After the wall cladding is applied, the inner core for the installation system may then be slotted or sat into the interior of the outer frame. The component to be installed may be formed integrally with the inner core inserted or alternatively may be removably engaged with the inner core and inserted into the cavity in the core 5 formed at the same time as the inner core or at a later time if required. Preferably the perimeter of the installed component, as seen by an observer, can extend substantially just to the edge of the outer frame and its intersection with the edges of the exterior cladding. This approach can substantially eliminate the need for a large covering flange to be 10 applied to the perimeter of installed components. In some instances, a relatively small foot may be formed on the perimeter of the component or the inner core to extend over the perimeter of the outer frame. This foot can be used to cover any small inconsistencies or cracks caused by stopping or filling compounds introduced between the edge of the exterior cladding and the interface surface or surfaces of 15 the outer frame. The present invention may also be used to solve timing problems associated with when components are installed and when a final finish or coat of paint is applied to a surface such as a wall, floor or ceiling. With use of the present invention, all the construction work and decorate finishes required may be applied to wall or surface 20 after the installation of the outer frame. The inner core may simply then be inserted into the outer frame once the wall has been finished, thereby eliminating the chance of the wall being damaged during the installation process, or in turn the component being damaged, or needing to be masked or covered prior to the application of paint to the surface involved. 25 11 BRIEF DESCRIPTION OF DRAWINGS Further aspects of the present invention will become apparent from the following description which is given by way of example only and with reference to the accompanying drawings in which: 5 Figure 1 shows a cross-section view of portions of a component installation system formed in accordance with a preferred embodiment when engaged with elements of a surface in which a component is installed, and Figures 2a - 2e show a series of cross section plan views illustrating the steps 10 involved with a method of installation employing the installation system shown with respect to figure 1. BEST MODES FOR CARRYING OUT THE INVENTION Figure 1 shows a cross-section view of portions of a component installation system formed in accordance with a preferred embodiment when engaged with elements of 15 a surface in which a component is installed. The portions of component installation system (1) shown includes an outer frame (2) which is to be connected to a structural element of a wall, floor or ceiling such as a component of a timber framing (3) shown. The outer frame includes a flange extending out from the body of the frame which sits on the top portion of the timber 20 framing element (3) where this flange can be nailed, screwed, bolted or otherwise adhered or attached to the framing. This provides a strong weight bearing connection from the outer frame to the structural elements of a wall for example, and thereby allows the installation system provided to support the weight of relatively heavy components. 12 The portion of the outer frame (2) shown also includes a single interface surface (4) which is adapted to contact the edge or perimeter of a section of exterior cladding applied to the wall or surface involved, with this cladding being shown by the plaster board section (5) illustrated in figure 1. As should be appreciated by those skilled in 5 the art, a plurality of interface surfaces are provided to define a perimeter for the outer frame, with each of these interface surfaces being placed directly in contact with the free or extended edge of the plaster board cladding of the wall or surface. The component installation system also includes an inner core (6) which sits within the outer frame (2). The component to be installed, which is shown in this 10 embodiment as an air conditioning grate or grill (7), in turn sits within the inner core (6). A friction fit is provided between the inner core (6) and air conditioning grill (7) to allow the grill to be slotted in and pulled out of the core. The component installation system also includes a frame connector, which in the embodiment illustrated is provided through a spring clip (8). The spring clip (8) 15 engages both the outer frame and inner core together to in turn secure and finish the installation of the air conditioning grill (7) into the wall involved. Figures 2a through 2e show a series of sequential perspective views illustrating the steps involved with a method of installation employing the installation system shown with respect to figure 1. 20 Figure 2a shows a view of a wall in the middle of construction where a wooden framework of structural elements (3) are provided without the wall yet including an exterior cladding. The installation system provided in accordance with the present invention is to be introduced at this stage of the construction of a wall. Figure 2b shows the initial stage of installation executed in conjunction with the 25 present invention. An outer frame (2) is introduced into a cavity between the 13 wooden studs and nogs of the structural framework. The edges or perimeter of this frame are directly connected to the wooden framing members (3) to provide a strong, load bearing connection of the installation system to the wall. Figure 2c shows the next stage in construction of both the wall and the 5 implementation of the installation involved. At this stage, an exterior cladding material in the form of plaster board sheets (5a) has been applied over the wooden framework, with a cavity in this cladding being formed in the vicinity of the outer frame. The edges or perimeter of these plaster board sheets are also placed in contact and engage with the interface surfaces formed in the outer frame preferably 10 leaving minimal or no gaps between these components. Furthermore at this stage a stopping, filling or corking compound (5b) is introduced at the interface between the edges of the wall cladding and the outer frames interface surfaces. Figure 2d shows the following stage and the installation completed, with the view provided showing the outer frame (2) shown in the prior views in cross section. At 15 this stage, an inner core (6) inserted into the outer frame which is now engaged with the perimeter of the cladding applied to the wall. The inner core is held in place with respect to the outer frame (2) by a series of spring clips (8). Figure 2e shows the final stage of installation to be completed wherein the component to be installed, shown in this embodiment as an air conditioning grill (7) 20 is inserted directly into the inner core (6). A friction fit between the inner core (6) and the grill (7) holds the grill in place. Aspects of the present invention have been described by way of example only and it should be appreciated that modifications and additions may be made thereto without departing from the scope thereof as defined by the appended claims. 14

Claims (19)

1. A component installation system adapted to install a component substantially within a surface, said installation system including, an outer frame adapted to connect the system to at least one structural 5 element used to form the surface within which a component is to be installed, said outer frame defining at least one interface surface adapted to contact an exterior cladding applied to the surface, and an inner core adapted to engage with the component to be installed, said inner core being adapted to sit substantially within said outer frame and to be 10 engaged with said outer frame.

2. A component installation system as claimed in claim 1 wherein the component to be installed is an air circulation component.

3. A component installation system as claimed in either claim 1 or claim 2, wherein the surface is a wall. 15

4. A component installation system as claimed in any of the previous claims wherein said at least one structural element is capable of supporting the weight of the component to be installed.

5. A component installation system as claimed in any of the previous claims wherein the outer frame is adapted to be directly secured to at least one 20 structural element.

6. A component installation system as claimed in any of the previous claims wherein a filling compound is used to contact at least one interface surface with an exterior cladding applied to the surface. 15

7. A component installation system as claimed in any of the previous claims wherein at least one interface surface defines the perimeter of the outer frame. 5

8. A component installation system as claimed in any of the previous claims wherein the inner core is adapted to be removably engaged with the component.

9. A component installation system as claimed in any one of claims 1 to 7 wherein the inner core is formed integrally with the component to be 10 installed.

10. A component installation system as claimed in any of the previous claims which includes at least one frame connector adapted to engage the inner core with the outer frame.

11. A component installation system as claimed in claim 10 wherein a frame 15 connector is adapted to releasably engage the outer frame with the inner core.

12. A component installation system as claimed in either claim 10 or claim 11 wherein a frame connector is formed from at least one spring clip.

13. A component installation system as claimed in any one of claims 10 to 12 20 wherein a frame connector includes at least one extending leg.

14. A component installation system as claimed in any one of claims 10 to 13 wherein the outer frame includes at least one projection adapted to engage with a frame connector.

15. A method of installing a component within a surface, comprising, 25 i) attaching an outer frame to at least one structural element of a surface, and 16 ii) applying an exterior cladding over said at least one structural element of the surface, said cladding being located in contact with at least one interface surface defined by said outer frame, and iii) inserting and retaining an inner core within the outer frame, said inner 5 core including the component to be installed.

16. A method of installing a component within a surface, comprising, (i) attaching an outer frame to at least one structural element of surface, and (ii) applying an exterior cladding over said at least one structural element of the surface, said cladding being located in contact with at least one 10 interface surface defined by said outer frame, and (iii) inserting and retaining an inner core within the outer frame, and (iv) engaging a component with the inner core to install the component substantially within the surface.

17. A method of installing a component within a surface as claimed in either 15 claim 15 or claim 16 wherein the component installed is an air circulation component.

18. A component installation system substantially as herein described with reference to and as illustrated by the accompanying drawings and/or examples. 20 17

19. A method of installing a component within a surface substantially as herein described with reference to and as illustrated by the accompanying drawings and/or examples. 5 Dated this Twenty Ninth day of July 2004. Holyoake Industries Limited 10 Applicant Wray & Associates Perth, Western Australia Patent Attorneys for the Applicant 15 18