GB2449088A

GB2449088A - Insulation device for electrical outlets

Info

Publication number: GB2449088A
Application number: GB0708890A
Authority: GB
Inventors: Ian Sawyer
Original assignee: V CUT Ltd
Current assignee: V CUT Ltd
Priority date: 2007-05-09
Filing date: 2007-05-09
Publication date: 2008-11-12
Anticipated expiration: 2027-05-09
Also published as: GB0708890D0; GB2449088B

Abstract

An insulation device 5,5A, for local insulation within a plasterboard wall incorporating switches and electrical outlets, is provided. The device comprises a box-like container made of paper-faced plasterboard. The box-like container is formed by making V-cuts in the plasterboard and folding along the cuts. The box may further incorporate a lid 12 which is formed as an additional panel on the box-like container. A v-cut joint down to the paper face along one edge of the open side of the container may act as a hinge for the additional panel forming the lid. A lining 6 may be inserted into the box-like container.

Description

INSULATION DEVICE FOR INSERTION INTO A WALL REQUIRING

INSULATION

FIELD OF THE INVENTION

This invention relates to improvements in insulation products.

BACKGROUND OF THE INVENTION

In new residential and office construction, increasingly strict standards of sound and thermal insulation are being required. For example, in the UK, the Building Regulations Approved Document F (2003 Edition) imposes various standards in respect of sound insulation of dwellings and other buildings. This is of particular importance for walls and floors separating different apartments and offices.

It is now common to construct dividing walls in buildings, and particularly housing, in dry-lined construction. This form of construction consists of metal or timber studs lined with plasterboards. Such plasterboards can be specially formulated boards such as fire-resistant or, in the case of dividing walls, sound-resistant boards in order to achieve the required insulation standards.

All of the major plasterboard manufacturers carry out tests to demonstrate compliance of their systems with the Building Regulations. However, these tests are carried on solid modules with no corners, windows, doors and, particularly, no cut-outs. The problem with these test constructions is that they do not take account of the practical need in any real building to incorporate services, in the form of outlet boxes, wall-sockets and switches, which require cut-outs to be made for these fittings in the plasterboard wall-panels. Such cut-outs then create weak points in terms of the sound or fire performance. Indeed, the mere cutting of holes in the wall can lead to non-compliance with Parts B and B of the UK Building Regulations. V There are a number of supplementary insulation products on the market, which seek to overcome the potential weak points created by cut-outs for outlet boxes and switches. These are all relatively expensive and can be time consuming, not to mention messy, to install. For example, HiltiTM produces rectangular putty pads, which are intended to be positioned behind wall-sockets and switch units before these are inserted in the cut-outs. At 2007 prices, such putty pads can cost, from Hilti, after client/bulk discount, around 8-fl 0 per pad depending on size, and every cut-out would require a pad.

Alternatively, the plasterboard manufacturers recommend local installation of secondary insulation with additional layers of boards, extra mineral wool and additional framing but, again, this is very labour intensive to install and adds to the costs of the materials.

SUMMARY OF THE INVENTION

It is an object of the present invention to overcome one or more of the disadvantages of conventional insulation products in these circumstances by providing an insulation device, which offers at least some of the following advantages: -which is relatively cheap to manufacture, being significantly below the cost for existing alternatives; -which allows flexibility in the alignment horizontally of switches and outlets as well as providing a simple means of insulating multiple or groupedlclustered outlets; -that uses sympathetic materials compatible with those used to construct the main wall; -that does not involve the construction of additional studding in a partition wall; -that is simple to install, not requiring substantial additional studding and boarding; -that avoids the need for extra cutting of boards on site, and the inherent dust and waste issues; -that makes use of the V-cutting technique and lime glue to create a strong insulating box; -that is not messy to install; and -which is unlikely to be displaced by an electrician's installation work (unlike some alternatives available on the market).

Thus, in accordance with one aspect of the invention, there is provided an insulation device for providing local insulation within a plasterboard wall incorporating switches and electrical outlets, the device comprising a 5-sided box-like container made of paper-faced plasterboard, wherein the box-like container has v-cut edges at all mating edges of the panels forming the box, and wherein the box panels may be fixed together along the v-cut edges to form an open-sided encasement for insertion into a walE. Preferably, the panels are glued together.

Lime glue may be used for this purpose. The panels may alternatively be fixed using tape or other suitable jointing method.

In accordance with another aspect of the invention, there is provided an insulation device, further comprising a lid, wherein the lid is formed as an additional panel on the box-like container with a v-cut joint down to the paper face along one edge of the open side of the container acting as a hinge for the additional panel forming the lid.

In a basic implementation, using V-cutting technology, a 5 sided box is constructed which, when glued together, forms a strong open-sided encasement that can be used for local insulation within a plasterboard wall incorporating switches and electrical outlets. The open side faces the wall board which will be cut for insertion of the switch/socket outlet. The box has V-cut edges, where the V-cut is made down to the paper face of the plasterboard, to allow the sides to hinge into the box shape.

The box can be manufactured from any type of plasterboard with a paper face and is designed to comfortably accommodate most common outlet and switch boxes and typically is made to fit between vertical framing studs set at either 400 or 600mm centres. For acoustic reasons, it is recommended to use 15mm sound-check boards, and for fire-rated walls, a suitable fire-rated board but any standard paper faced plasterboard may be used.

When a lid is incorporated on the open side of the box, the box can conveniently be made deeper to protrude out from the wall cavity so that when closed the lid is flush with the wall boards fixed around it, when accurately installed.

The lid is formed intact with the box by the formation of a V cut joint down to the paper face along the bottom or top edge, i.e. it is not cut through. This allows the lid to "hinge" along the edge, which is not cut through, providing access to the full open face of the box when the lid is open.

The lid has the advantage that it facilitates easier installation of the electrician's fittings. When the wiring and outlets are completed, the lid can be glued shut or, with the addition of additional fitments inside the box, screwed shut. The joints around the box can then be taped and jointed, or where required, skimmed, to achieve a seamless finish.

The dimensions for the box can be totally flexible. In plasterboard walls the metal or timber studs are normally spaced at 400 and 600 centres. A standard version of the box can be made to suit these usual stud centres. All the dimensions, however, are capable of adjustment to suit unique applications.

The box can be ready-made with any paper-faced plasterboards with up to 20mm thickness of board. Fire, sound, standard, or moisture-resistant boards can be used.

A hole for wiring or conduit can be pre-cut in the top or bottom of the box.

The box can be further lined with plasterboard or other inserts or formed as a box within a box to increase the insulation properties and/or strength, e.g. fire/sound resistance.

The term "V-Cutting Technology" is used herein to refer to a process for economically producing pre-manufactured plasterboard profiles. The process involves cutting grooves into the plasterboard so that it may then simply be folded to the required shape. This allows easy, quick and high quality constructionlinstallation. Heretofore, V-Cutting Technology has been used principally for shaping plasterboard wall-boards to fit around corners in a room or to form bulkheads in plasterboard ceilings.

DESCRIPTION OF DRAWINGS

The invention will now be described in detail with reference to the accompanying drawings, in which: FIG. I shows the basic construction of an insulation device according to the present invention; FIG. 2 shows further views of the basic construction of an insulation device according to the present invention; FIG. 3 is an exploded view illustrating a typical installation of the device in Fig. 2; FIG. 4 shows sectional views of an alternative embodiment of an insulation device according to the present invention; FIG. 5 is a view illustrating a typical installation of the device of Fig. 4; FIG. 6 is a view illustrating a typical installation of a variation of the device of Fig. 4 Where dimensions are indicated on the Figures, they are in mm and are given by

way of example only.

DETAILED DESCRIPTION

Fig. 1 illustrates the basic construction of an insulation device according to the present invention. Fig.1(a) shows how five panels may be cut out from a plasterboard sheet, with v-cutting technology used to chamfer the mating edges between each of the back panel 2, side panels 3 and upper and lower panels 4. In the illustrated embodiment 1, the v-cutting technique has been used to hinge each of the panels 3 and 4 from the rear panel 2. It will be apparent to the skilled man that alternative hinging arrangements may be employed for folding into a five-sided box 5. For example, one or both side panels 3 could be hinged from either upper or lower panel 4 or vice-versa.

As shown in Fig. 1(b), after cutting, the panels are folded and glued along the mating v-cut edges to create a 5-sided box 5. Optionally, as shown in Fig. 1(b) and 1(c), for additional insulation and/or strength, inserts 6 may be fitted into the basic box. The inserts may be also of plasterboard (and may also be made by v-cutting a smaller size box to fit) or of other suitable insulating and/or reinforcing material.

Fig. 1(c) is a vertical cross-section through the box 5 of Fig. 1(b), with the optional inserts 6 shown in place.

Fig. 2 illustrates a basic box 5 (shown without inserts 6) in perspective view, in vertical cross-section and in front view. The v-cut joints between the mating panel edges 2-4 and 3-4 are shown.

Fig. 3 illustrates a typical installation of an insulation device according to the present invention. The box 5 (without additional inserts) is fitted between two studs 7 in a stud-partition wall. In the illustrated installation, the box is fixed to the studs 7 with screws 8. If the studs were wood, for example, the box 5 could be fixed with staples, taped or glued in place. Other fixing options may be employed without affecting the invention. In this installation, a plasterboard wall panel 9 is fitted over the box. The wall-panel 9 is provided with a cut-out 10 to allow installation of a wall socket 11. It will be evident that the box 5 acts to provide supplementary insulation to replace that which would otherwise be lost by making the cut-out 10 in the wall panel 9.

Fig. 4 shows in vertical and horizontal cross-section, a modified box 5A with a lid 12 on the open side of the box. The box 5A is shown in position between studs 7 in a stud-partition wall, and with wall panels 13 to the front and rear. In this modified embodiment of an insulation device according to the present invention, the side panels 3A and top and bottom panels 4A have v-cut edges to the open-side, and the lid 12 is shown with v-cut edges and hinged to the lower of the panels 4A.

As illustrated in the horizontal plan view in Fig. 4, the lid 12 may be closed and glued in place. Optionally, as shown, fitments 14 may be provided to allow the lid to be held in place by screws 15. Twist-lock fittings may be used in place of screws. Use of screws or equivalent means to secure the lid in place of glue (rather than in addition to glue) would allow the lid to be more readily reopened, if necessary. In this embodiment, the side panels 3A and top and bottom panels 4A extend out from the wall cavity so that, when closed, the lid 12 is flush with the wall panel 13 on that side.

Fig. 5 is a perspective view of the installation of the embodiment of Fig. 4 in a stud-partition wall. The box 5A is held by screws 8 between studs 7. The lid 12 is shown with v-cut edges and hinged down from the lower panel. The lid 12 is provided with a cut-out 10 to allow fitting of a wall socket or switch unit. In this case, optional angle-brackets 14 are provided to allow the lid 12 to be screwed closed. A further cut-out 16 is provided in the upper panel of box 5A to allow entry of cables and/or conduit.

It is not essential for the lid to fit the top of the box exactly. As shown in Fig. 6, optionally, the lid 12A may be extended to suit the requirements of any particular installation. For example, the lid 12A may conveniently be extended to match the relevant stud spacing, so that plain plasterboard wall panels may then be positioned simply to abut the box lid 12A above and below.

Claims

CLAIMS: 1. An insulation device (5) for local insulation within a

plasterboard wall incorporating switches and electrical outlets, the device comprising: a five-sided box-like container made of paper-faced plasterboard, wherein the box-like container has v-cut edges at mating edges of each side of the box, wherein the v-cut mating edges are fixed together to form an open-sided encasement for insertion into a plasterboard wall.
2. A device (5A) according to claim 1, further comprising a lid (12), wherein the lid is formed as an additional panel on the box-like container with a v-cut joint down to the paper face along one edge of the open side of the container acting as a hinge for the additional panel forming the lid.
3. A device (5A) according to claim 2, wherein the lid (12) is provided with a cut-out (10) for installation of a wall-socket or switch unit.
4. A device according to claims 1, 2 or 3, wherein the v-cut mating edges are fixed together with lime glue.
5. A device according to claim 2 or 3, further comprising fitments (14) on the inside of the box-like container, adapted to receive screws or twist-lock fixings to secure the lid in closed position.
6. A device according to any preceding claim, wherein the paper-faced plasterboard is up to 20mm thickness.
7. A device according to any preceding claim, wherein the paper-faced plasterboard is fire, sound, standard or moisture-resistant plasterboard.
8. A device according to any preceding claim, further comprising at least one aperture (16) in the top or bottom of the container to allow entry of wiring or conduit.
9. A device according to any preceding claim, further comprising one or more insert(s) (6) for increased insulation and/or strength.
10. A device according to any preceding claim, wherein the plasterboard is 15mm for acoustic insulation.
11. A device according to any preceding claim, wherein the plasterboard is 12.5mm for standard insulation.
12. A device for improving insulation within a plasterboard wall, the device being substantially as described herein and with reference to Figures 1 to 6.