AU785185B2 - Wall plate for electrical device - Google Patents

Description

-7 S&FRef: 592872

AUSTRALIA

PATENTS ACT 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT

ORIGINAL

a a Name and Address of Applicant Actual Inventor(s): Address for Service: Invention Title: AF Inventions Pty Limited 2 Gloucester Avenue Merrylands New South Wales 2160 Australia Raymond Stephen Frangi, Bruce Sharpe Spruson Ferguson St Martins Tower,Level 31 Market Street Sydney NSW 2000 (CCN 3710000177) Wall Plate for Electrical Device ASSOCIATED PROVISIONAL APPLICATION DETAILS [33] Country [31] Applic. No(s) AU PR4174 AU PR9359 [32] Application Date 03 Apr 2001 06 Dec 2001 The following statement is a full description of this invention, including the best method of performing it known to me/us:- ,P~uS~raCh o 1.

I 5815c 1i. SEP. 2006 10:58 SPRUSON F--RGUSON 92615486 JO. 1554 P. 11

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WALL PLATE FOR ELECTRICAL DEVICE Field of the Invention The present invention relates generally to the finishing of wall surfaces in the immediate area surrounding a wall mounted electrical device in newly constructed or s renovated buildings and homes and, in particular, to an apparatus for use in the installation of a wall mounted electrical device in newly constructed or renovated buildings and homes.

Background In the construction and renovation of buildings and homes, the installation of wall mounted electrical devices such as light switches and power outlets, for example, involve the use of a wall plate for mounting the required electrical device. Once the wall plate is attached to the wall structure, wall finishing personnel apply a surface finishing "material such as cement render, plaster, or the like. Notably, when finishing the wall surface in the immediate area surrounding the wall plate, it is often the case that excess surface finishing material is inadvertently applied to the receptacle intended for the Se electrical device. This usually results in a poor quality finish in the wall surface surrounding the electrical device and creates difficulties for electrical personnel who have to remove the excess finishing material from the wall plate receptacle to enable installation of the electrical device. This process often results in damage to the surface 20 finish of the wall in the area surrounding the wall plate and/or damage to the electrical device receptacle. As a consequence, time and money are wasted in reworking the wall surface finish and/or repairing the electrical device receptacle of the wall plate.

Summary of the Invention It is an object of the present invention to substantially overcome, or at least ameliorate, one or more of the deficiencies of the prior art.

In accordance with one aspect of the invention there is disclosed an apparatus for the installation of an electrical device to a wall, said apparatus comprising: a plate having a cut-out forming a receptacle for the electrical device, the plate being configured for attachment to the wall to mount the electrical device when installed; and (R:\LIBOO)4965.doc:eaa COMS ID No: SBMI-04714635 Received by IP Australia: Time 11:01 Date 2006-09-11 11. SEP. 2006 10:59 SPRUSON FERGUSON 92615486 NO. 1554 P. 12 -2at least one flange arranged about said receptacle and extending from a plane of said plate to define a plane substantially parallel to said plate and by which a finishing material can be applied to the wall, over the plate, and about the flange.

In accordance with another aspect of the invention there is disclosed a method s for wall surface finishing in an area intended for the mounting of an electrical device, said method comprising the steps of: a) attaching the apparatus mentioned above to a wall structure; and b) applying a wall finishing material in a plane substantially parallel to said plate; and to c) applying a wall finishing material to a depth substantially equal to that of said flanges; and d) applying a wall finishing material surrounding said receptacle bounded by said flanges.

SIn accordance with another aspect of the invention there is disclosed an apparatus 15 for the installation of an electrical device to a wall, said apparatus comprising: a plate having a cut-out forming a receptacle for the electrical device; and at least one flange offset a nominal distance from an edge of said receptacle and extending from a plane of said plate and by which a wall finishing material can be applied; a first securing means for securing the apparatus onto the wall is provided on said plate; and second securing means located between said flanges and said edge of receptacle for mounting the device to the apparatus.

Brief Description of Drawings At least one embodiment of the present invention is described hereinafter with reference to the drawings, in which: Fig. a is a perspective view of a first arrangement of a wall plate; Fig. b is a plan view of the wall plate of Fig. 1 a; Fig. c is an inverted plan view of the wal plate of Fig. a; Fig.2a is a front view of the wall plate of Fig.la; [I1\LIBOO]4965.doc:eaa COMS ID No: SBMI-04714635 Received by IP Australia: Time 11:01 Date 2006-09-11 -3- Fig.lc is an inverted plan view of the wall plate of Fig.la; Fig.2a is a front view of the wall plate of Fig.1 a; Fig.2b is a side view of the wall plate of Fig. 1 a; Fig.3 is a rear view of the wall plate of Fig. 1 a; Fig.4a is a perspective view of the wall plate of Fig.la being fitted with a receptacle protection cover; Fig.4b is a section view of the arrangement of Fig.4a with the cover fitted in position; Fig.4c is a section view of the wall plate of Figs.la to 4b, as installed in a completed wall; is a perspective view of the wall plate of Figs. la to 3 having an alternate method of fixing; is a section view of the wall plate of Fig.5a, as installed in a completed wall; 15 Fig.6a is a perspective view of a second arrangement of a wall plate; *Fig.6b is a plan view of the wall plate of Fig.6a; Fig.6b is an inverted plan view of the wall plate of Fig.6a; Fig.7a is a perspective view of the wall plate of Fig.6a; Fig.7b is a section view showing the interlocking relationship between the angled finishing flanges on separate wall plates of Fig.6a; Fig. 8a is a perspective view of a third arrangement of a wall plate; Fig. 8b is a plan view of the wall plate of Fig. 8a; Fig. 8c is a inverted plan view of the wall plate of Fig. 8a; Fig. 9a is a front view of the wall plate of Fig. 8a; Fig. 9b is a rear view of the wall plate of Fig. 8a; Fig. 9c is a right side view of the wall plate of Fig. 8a; Fig. 10a is a perspective view of the wall plate of Fig. 8a; and Fig. 10b is a section view of the wall plate of Fig. 8a as installed in a completed wall.

[R:\LIBOO]496S.doc:mxa -4- Detailed Description Including Best Mode Fig.la shows a perspective view of a wall plate 100 for mounting electrical devices such as light switches, general purpose outlets, and the like. The wall plate 100 has a rectangular back plate 110 having a receptacle 120 for the electrical device (not illustrated). The electrical device is attached to the back plate 110 by means of a pair of captive threaded nuts 170 mounted at the rear of the back plate 110 and located on either side of the receptacle 120. The screw cut-out 180 allows fixing screws (not shown) associated with the electrical device to pass through the front side of the back plate 110 to the captive threaded nut 170 at the rear.

The periphery of the back plate 110 is provided with a series of holes 130 and 140 by which the wall plate 100 can be attached to the wall of a building using nails, screw fixings, and the like. In addition, the back plate 110 has a series of larger holes 150 in the area between the edges of the back plate 110 and the receptacle 120. The larger holes 150 are provided to enable better adhesion of surface finishing material to the surface of the wall plate 100.

The receptacle 120 is formed by a cut-out in the back plate 110. The cutting-out S•of the receptacle 120 is used to form finishing flanges 160 on each side of the receptacle 120. The flanges 160 are bent at approximately 90' to the surface of the back plate 1 10 as *shown in Figs.lb and Ic. A front view of the wall plate as it would appear when installed is shown in Fig. 2a, with the finishing flanges 160 protruding outwards from the surface of the wall and defining a plane by which a finishing material such as cement render may be applied to cover the wall plate 100. Fig. 2b shows a housing 171 for the captive threaded nut 170 which is mounted at the rear of the back plate 110 facing towards the surface of the wall (not illustrated). The rear view of the wall plate 100 of Fig. 3 shows the captive threaded nut 170 and the nut housing 171 which is riveted or spot welded, or the like, to the rear of the back plate 110.

In a preferred configuration the receptacle 120 is provided with a removable protective cover 190 as shown in Figs. 4a and 4b, wherein the removable protective cover 190 is mounted over the finishing flanges 160 of the receptacle 120 using an interference R:\LIB0014965.doc:nxl fit. Fig. 4c shows a sectioned view of the wall plate 100 as attached to the wall 200 and illustrates how the finishing flanges 160 provide both a guide for the application of surface finishing material 210 and also to prevent excess material from being deposited within the receptacle 120. The protective cover 190 can be used in addition to the finishing flanges 160 to further protect the receptacle 120 from the ingress of excess material. The example installation shown in Fig.4c uses nails 220 to attach the back plate 110 to the wall 200. Alternatively, Figs. 5a and 5b illustrate a fixing method using double-sided adhesive tape 221, or the like.

A second arrangement of a wall plate 300 shown in Fig. 6a where like reference numerals refer to like components of the wall plate 100. In the wall plate 300, the electrical device receptacle 120 is formed by a cut-out in the rectangular plate 110, wherein a finishing flange 310 formed on each side of the receptacle 120 is bent at an angle to the surface of the back plate 110, this being better illustrated in Figs. 6b and 6c.

The finishing flanges 310 provide both a guide for the application of surface finishing material 210 and also to prevent excess material from being deposited within the receptacle 120. In addition, the angled feature of the finishing flanges 310 enables one wall plate 300 to physically interlock with another wall plate 300, as illustrated in Figs. 7a :and 7b, for improved storage and bulk transportation of the wall plates 300. Also, in o order that the depth of finishing material is maintained to that of the arrangement of, say, Fig. 4c, the width of each flange 310 would typically be greater than the corresponding 00 width of each flange 160.

Figs. 8a to 10b show a third arrangement in respect of a wall plate 400 where like reference numerals refer to like components of wall plate 100. The perspective view of the wall plate 400 shown in Fig. 8a illustrates a rectangular back plate 410 having a receptacle 120 for an electrical device (not illustrated). The electrical device is attached to the front of the back plate 410 by means of a pair of captive threaded nuts 170. The captive threaded nuts 170 and the nut housing 171 are riveted or spot welded, or similarly secured, at the rear of the back plate 410 as shown in Fig. 9b. The nut housing 171 and captive threaded nut 170 are located on either side to the edges 520 of the receptacle 120.

[R:\L1Bo14965.doc:mxl As illustrated in Figs. 8b, 8c, 9a, 9b and 9c, the back plate 410 is cut, bent and/or pressed to form a number of finishing flanges 460. The finishing flanges 460 are offset each edge 520 of the receptacle 120 a nominal distance to allow a nut housing 171 to be secured in between a finishing flange 460 and the edge 520 of the receptacle 120. The finishing flanges 460 run parallel to the edges 520 of the receptacle 120. This allows a surface finishing material 210 to be applied as shown in Fig. 10b. The finishing flanges 460 act as a guide for the application of the surface finishing material 210 to prevent excess material being deposited on either screw mount 170 and between the receptacle 120 and the finishing flanges 460.

The periphery of the back plate 410 is provided with a series of holes 130 and 140 by which the wall plate 400 can be attached to the wall of the building 200 using nails 220, screw fixing and the like as illustrated in Figs. 10a and 10b. Large holes 150 are provided in the area between the edges 640 of the back plate 410 and the finishing flange 460 to enable better adhesion of the surface finishing material.

The screw cut out 180 shown in Fig. 9a, allows for fixing screws (not shown) associated with the electrical device to pass through the front side of the back plate 410 via the captive threaded nut 170. The location of the nut housing 171 is positioned to match the screw layout of the associated electrical device.

Industrial Applicability It is apparent from the above that the arrangements described are applicable to the construction industry in the area of a wall mounted electrical device installation and wall surface finishing in a wide range of building applications.

The foregoing describes only some embodiments of the present invention, and modifications and/or changes can be made thereto without departing from the scope and spirit of the invention. For example, in each of the described arrangements, rectangular cut-outs are shown. Similarly, each embodiment contains flanges 160, 310, 460, although the precise location may differ. Where appropriate, a circular cut-out may be formed [R:\LIBOO]4965.doc:mxl giving rise to a single flange. Such an arrangement may be formed by a cut and press operation similar to that used to form the arrangements illustrated herein.

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Claims (14)

1. An apparatus for the installation of an electrical device to a wall, said apparatus comprising: a plate having a cut-out forming a receptacle for the electrical device, the plate being configured for attachment to the wall to mount the electrical device when installed; and at least one flange arranged about said receptacle and extending from a plane of said plate to define a plane substantially parallel to said plate and by which a finishing to material can be applied to the wall, over the plate and about the flange.

2. An apparatus as claimed in claim I, wherein said flanges are formed substantially perpendicularly from said plate and collectively a periphery of each of said flanges define said substantially parallel plane.

3. An apparatus as claimed in claim 1 or 2, wherein said flanges are formed at an angle from said plate such that a plurality of said apparatus can be physically interlocked upon stacking for transportation.

4. An apparatus as claimed in any one of the preceding claims, wherein said receptacle is provided with a protective cover.

An apparatus as claimed in any one of the preceding claims, wherein said flange(s) are formed in a space between said cut-out and a periphery of said plate.

6. Apparatus according to claim 5 further comprising attachment means by which said electrical device can be affixed to said apparatus, said attachment means being formed in said plate between said cut out and said flanges. (R:LIBOO4965.doc:ea COMS ID No: SBMI-04714635 Received by IP Australia: Time 11:01 Date 2006-09-11 SEP. 20C6 10:59 SPRUSCN FERGUSON 92615486 1554 P. 14 -9-

7. Apparatus for the installation of an electrical device to a wall, said apparatus comprising: a plate having a cut-out forming a receptacle configured for the receiving of said electrical device; at least one flange arranged between said cut-out and a periphery of said plate and extending from a plane of said plate so as to form a barrier around said receptacle to prevent a wall finishing material from entering said receptacle; a first securing means provided on said plate for affixing the apparatus onto the wall; and a second securing means for affixing said electrical device to said apparatus, o'o wherein said second securing means is located in between said flange(s) and said cut-out. 9

8. An apparatus as claimed in of claim 7, wherein said flange(s) is formed from at least one of cutting, pressing and bending of said plate.

9. An apparatus as claimed in claim 8 wherein said flange(s) are angled from plane of said plate.

10. An apparatus as claimed in any one of claims 8 or 9 wherein at least one nut housing for the mounting of said electrical device is secured in between said receptacle and said flange(s).

11. An apparatus as claimed in claim 10 wherein said first securing means is formed from holes on said plate,

12. An apparatus as claimed in claim 11 comprising four of said flanges located on each sides of a rectangular said receptacle and running substantially parallel to said edges of receptacle at a height to form a plane parallel to said plate. [R:\LBOO]4965.doc:Ca COMS ID No: SBMI-04714635 Received by IP Australia: Time 11:01 Date 2006-09-11 11. SEP 2006 10:59 SPRUSON FERGUSON 92615486 NO 1554 P.

13. Apparatus substantially as described herein with reference to Figs. 1 to Sb, of the accompanying drawings.

14. Apparatus substantially as described herein with reference to Fig, 6a to 7b of the s accompanying drawings. Apparatus substantially as described herein with reference to Figs. 8a to 10b of the accompanying drawings. j0 16. A method for wall surface finishing in an area intended for the mounting of an electrical device, said method comprising the steps of: a) attaching apparatus as claimed in any one of the preceding claims to a wall structure; and b) applying a wali finishing material in a plane substantially parallel to said plate; and c) applying a wall finishing material to a depth substantially equal to that of said .eee flanges; and d) applying a wall finishing material surrounding said receptacle bounded by said flanges. DATED this eleventh Day of September, 2006 AF Inventions Pty Limited Patent Attorneys for the Applicant SPRUSON FERGUSON (R:\LMOO1495.doc:eaz COMS ID No: SBMI-04714635 Received by 1P Australia: Time 11:01 Date 2006-09-11