GB2593202A

GB2593202A - Aperture liner and method

Info

Publication number: GB2593202A
Application number: GB2003999.6A
Authority: GB
Inventors: Antony Marston Smith Richard
Original assignee: Individual
Current assignee: Individual
Priority date: 2020-03-19
Filing date: 2020-03-19
Publication date: 2021-09-22
Also published as: GB202003999D0

Abstract

An aperture liner 10 is provided for lining an aperture in sheet material such as a plasterboard ceiling panel. The liner 10 is in the form of a hollow body 16, the outer surface of which carries a plurality of spaced fins 26 each of which is attached to the body 16 in a resilient manner. A downlight may be installed in the aperture.

Description

APERTURE LINER AND METHOD

FIELD OF THE INVENTION

The present invention concerns an aperture liner for lining an aperture in sheet material and a method of positioning of, for example, an electrical fitting in an aperture formed in sheet material.

BACKGROUND TO THE INVENTION

Light fittings, such as downlights, are often fitted into holes or apertures formed in ceiling sheet material such as plasterboard. Those apertures can become worn, for example, as a consequence of repeated replacement of the light fitting, or may simply be inaccurately cut. Moreover, if a light fitting is to be replaced, the aperture may be too big for the new light fitting. In addition, it is sometimes necessary to re-plaster over redundant apertures, for example, if a light fitting is to be re-positioned. There is a need for a device to assist in overcoming these problems in a convenient and neat manner.

We are aware of International Patent Publication No. 2015/173593 (Stevens) which describes a liner for lining an aperture in plasterboard. In one described embodiment, the liner has a generally circular ring which carries a number of non-resilient deformable triangular tabs, the pointed end of each tab serving to pierce the plasterboard into which the liner is fitted.

It is an object of the present invention to improve on the liner device described by Stevens.

SUMMARY OF THE INVENTION

We have surprisingly, through extensive research and development, discovered that this objective can be achieved where the liner is provided with strakes or fins which are resiliently mounted on the body of the liner.

Thus, according to the invention, there is provided an aperture liner for lining an aperture in sheet material, the liner being in the form of a hollow body, the outer surface of which carries a plurality of spaced fins each of which is attached to the body in a resilient manner. -2 -

Using fins which are resiliently mounted on the body of the liner allows the liner to be inserted into an aperture which has a diametric dimension greater than the outer diameter of the body. On insertion into the aperture, the fins will flex so that they occupy the space between the outer surface of the body and the edge of the aperture. The fins allow both upwards and downwards movement of the liner, as well as rotation in order to locate the liner within the aperture. The fins allow the liner to be used with both smooth apertures and apertures having an irregular shape. They also allow the liner to be used with apertures having a broad range of diameters. This means that the liner can be used with both new and existing downlight apertures.

Unless the liner is used with a very close-fitting aperture, plaster will typically be applied over and under the fins, and finished so as to provide a completely flat surface, which is flush with the surrounding plasterboard. As the fins are resiliently attached to the body, they will squeeze the plaster so that the plaster forms a firm bond to both the liner and the aperture.

At rest, each of the fins preferably extends in a common circumferential direction, preferably at an angle to a tangent of the body where the fin is attached, more preferably at an acute angle to a tangent of the body where the fin is attached. This will aid insertion of the liner in the aperture and rotation of the liner so as to locate the liner within the aperture.

Preferably, each fin comprises a proximal edge connected to said outer surface of said body, an opposite distal edge, an upper edge and a lower edge. This will mean that the fins have sufficient area to provide a good keying surface for the plaster.

Each fin may be substantially rectangular.

In use, the distal edge of the fins will engage the edge surface of the aperture, thereby holding the liner in the aperture.

The distal edge may extend in a direction substantially parallel to the axis of the body.

The distal edge may extend in a direction at an angle to the axis of the body, preferably at an acute angle to the axis of the body. This will mean that, in use, the fins will be tilted to the vertical, with the result that the fins will support plaster applied from above, thereby preventing the plaster from falling through the gaps in between the fins before it has a chance to set. -3 -

At least part of each lower edge may extend upwardly towards the upper edge of the fin. This will facilitate application of plaster from below using a sealant gun. Preferably, less than half of the lower edge extends upwardly towards the upper edge of the fin. Such a lower edge will still facilitate application of plaster from below without substantially reducing the keying surface area provided by the fins.

The liner may comprise fins having a length which occupies from a quarter to three quarters, preferably two thirds to three quarters, of the circumferential distance between the fins.

Typically, the liner comprises from 8 to 24 the fins. More specifically, liners having diameters of 50, 70 or 85 mm will typically carry respectively 10, 15 or 20 fins.

The distal edge of the fins may have one or more protrusions. These will provide further grip in the event that the aperture has smooth sides.

The upper edge of the body may comprise strengthening means, for example a flange. The flange may be joined to and contiguous with part of the top edges of the fins. If the liner is plastered, the flange will provide support for the liner, such that the liner resists downward motion. If the liner is used in close-fitting holes and not plastered, the flange serves to constrain the fins providing greater resistance at the top against downward forces and hence movement.

The flange may be shaped so as to enable a number of liners to be stacked together.

The fins may be integral with the body. Alternatively, the fins may be hinged to the body. If the fins are hinged to the body, then they should be supported by a web so that the fins are attached to the body in a resilient manner. This web may be rhomboid.

The fins should be made of a material which is stiff enough to hold the insert and any plaster applied within the aperture, for example, during setting of the plaster. If the fins are integral with the body, then the fins should be made of a material which is sufficiently resilient to allow the fins to flex to accommodate differences in the size of the aperture and irregularities in the edges of the aperture, but without permanent yielding so that the fins return to their original shape after the liner has been inserted in the aperture.

The fins are preferably formed of a plastics material, such as polycarbonate, or of a metal such as aluminium. -4 -

The body is preferably formed of a plastics material, such as polycarbonate, or of a metal such as aluminium.

The materiafis) of which the body and the fins are formed is/are ideally fire retardant.

The aperture liner may be formed by a process comprising injection moulding. The hollow body is preferably substantially cylindrical.

The hollow body may taper from the upper edge of the body to the lower edge of the body. This will facilitate removal of the body from the mould in the event that the body is made by injection moulding. It will also provide additional resistance to downward force applied by downlight springs.

Thus, the invention also provides a method of positioning an electrical fitting in an aperture formed in sheet material, comprising inserting an aperture liner according to the invention into the aperture with the lower edge of the body not protruding beyond the lower face of the sheet material, wherein the aperture has a dimension wider than the body, filling the space between the outer surface of the body and the edge of the aperture with settable material and thereafter inserting the electrical fitting into the hollow space within the body.

The sheet material may be plasterboard.

The electrical fitting may comprise a downlight, for example wherein the downlight includes spring clips which, when the downlight is in position, press against the upper surface of the sheet material.

The electrical fitting does not have to be mounted within the body straight away. Accordingly, the liner could be used to prevent damage to plasterboard pending later installation of electrical fittings, for example, when alternative downlight retrofitting is required, or when other fittings are to be used.

The liner has other uses apart from installation of electrical fittings. The liner may comprise a web which extends across the hollow body, the web being formed from a plurality of fins. This mean that the liner can be used for complete sealing of an existing aperture. Once the liner has been inserted in the aperture, plaster may be applied over and in between the fins on the outer surface of the body and the fins which form a web which extends across the body so as to completely fill the -5 -aperture. A plasterer's trowel may then be used to form a smooth surface contiguous with the plasterboard which surrounds the aperture.

The web may include a ring at the centre of the hollow body. This ring may be used to accommodate a mandrel in order to enlarge the aperture or make a minor adjustment in the position of the aperture.

The web may be provided in the form of an insert. The liner can than adapted to include a web as and when required.

The body may include internal features such as indents or threads to allow the insert to be secured.

In this embodiment, the hollow body may be substantially cylindrical. Alternatively, it may be in the form of a ring. Where the hollow body is in the form of a ring, it is anticipated that the liner will be used solely for complete sealing of an aperture.

The liner is designed to be used as part of a fast-finishing plastering process and does not require high skill levels. It is anticipated that for example ten apertures could be neatened, or repaired, in about 20 minutes.

In preferred embodiments, the liner comprises an injection-moulded one-piece assembly. A cylindrical ring of just greater thickness than the plasterboard has external flexible fins set at about 45 ° with angled leading edges to facilitate fitting. The fins are angled to allow clockwise adjustment (as a convention) from below and are long enough to provide sufficient grip with the existing fresh or rough aperture surface. The plastic material is sufficiently flexible to allow some compression without permanent yielding to allow fitting but stiff enough to return to its original shape and to be sanded flat with the ceiling if not fitted entirely accurately. An internal rim allows for an optional insert to click into place when fitted from below to provide keying surfaces and support for complete plastering over. A thin annular disc, to the top of the device when fitted, is an optional feature which would allow more secure temporary location, e.g. prior to plastering, and would have the added feature of being pulled down by the fins, in a tight-fitting aperture, over any burr in the drilled plaster aperture.

INTRODUCTION TO THE DRAWINGS

The invention will now be further described, by way of example, with reference to the accompanying drawings, in which: -6 -Figure 1 is a perspective view of an embodiment of an aperture liner according to the invention Figure 2 is a cross-sectional view of the liner shown in Figure 1, inserted in an aperture in plasterboard sheet material; Figure 3 shows the liner of Figure 1, viewed from below; Figure 4 is a view similar to Figure 3, where the liner has been inserted in a rough and damaged aperture in plasterboard sheet material; Figure 5 is a cross-sectional view of the liner shown in Figure 1, together with a downlight light fitting; and Figure 6 shows the liner of Figure 1 with an insert, viewed from below. DESCRIPTION OF ILLUSTRATED EMBODIMENTS The drawings show an aperture liner 10 for lining an aperture 12 in sheet material 14 The liner 10 is in the form of an injection moulded hollow cylinder 16 having a diameter of approximately 70 mm, a thickness of about 1.5 mm and a depth of about 14 mm formed of polycarbonate and defining a hollow space 46 about an axis A. The upper edge 22 of the cylinder 16 comprises strengthening means in the form of an annular flange 18.

The outer surface 20 of the cylinder carries 15 integrally formed spaced strakes or fins 26 each of which is attached to the cylinder 16 in a resilient manner. At rest, the fins 26 extend in a common circumferential direction D at an acute angle of 45° to a tangent of the cylinder 16 where the fin 26 is attached. Each fin 26 has a thickness of about 0.5 mm, a length of 10 mm and is substantially rectangular, including an 11 mm proximal edge 28 connected to the outer surface 20 of the cylinder 16, an opposite distal edge 30 parallel to the proximal edge 28, an upper edge 32 extending substantially at right angles to the axial direction A, and a lower edge 34, which extends from the proximal edge in a direction substantially parallel to the upper edge 22, and, about half way along, changes direction so that it extends upwardly towards the upper edge 32 of the fin 26.

When the liner 10 is inserted in an aperture 12 in sheet material 14 where the aperture 12 has a diametric dimension greater than the outer diameter of the -7 -cylinder 16, the fins 26 occupy the space 36 between the cylinder 16 and the annular edge surface 38 of the aperture 12.

As seen from Figure 4, the liner has been inserted in a rough and damaged aperture 12 in plasterboard sheet material, providing a template for plastering, the fins 26 being deformed, the liner being self-centering, secured and forces balanced, by rotation of the liner prior to plastering. The liner is inserted from below, rotated into the aperture and rotated downward into place. A straight edge e.g. plasterer's trowel, can be used to align the device with the ceiling for subsequent finishing with for example a quick-setting plaster, or plaster in a sealant gun.

As seen from Figure 5, in use, a downlight 40 is positioned in the aperture 12 formed in plaster board ceiling sheet 14, by inserting the aperture liner 10 into the aperture 12 with the lower edge 24 of the cylinder 16 not protruding beyond the lower face 41 of the plaster board 14. The aperture 12 has a dimension wider than the cylinder 16 so generating the space 36 between the outer surface 20 of the cylinder 16 and the edge of the aperture 12. This space 36 is then filled with sellable material 42 and thereafter the downlight 40 is inserted into the hollow space 43 within the cylinder 16. The downlight includes spring clips 44 which, when the downlight is in position, press against the upper surface 48 of the sheet material 14.

As seen from Figure 6, the liner may be used with an insert which comprises a plurality of additional fins 50 which form a web which extends across the interior of the hollow cylinder 16 (shown as a dotted line). The cylinder 16 includes internal features such as indents or threads to allow the insert to be secured.

The insert allows the liner to be used for complete sealing of an existing aperture. Once the liner has been inserted in the aperture, plaster may be applied over and in between the fins 26 on the outer surface of the cylinder 16 and the additional fins 50 which form a web which extends across the interior of the cylinder 16 so as to completely fill the aperture. A plasterer's trowel may then be used to form a smooth surface contiguous with the plasterboard which surrounds the aperture.

The web includes a ring 52 at the centre of the hollow cylinder 16. This ring 52 may be used to accommodate a mandrel in order to enlarge the aperture or make a minor adjustment in the position of the aperture.

Claims

CLAIMS1 An aperture liner (10) for lining an aperture (12) in sheet material (14), the liner (10) being in the form of a hollow body (16), the outer surface of which carries a plurality of spaced fins (26) each of which is attached to the body (16) in a resilient manner.
2. An aperture liner according to claim 1, wherein, at rest, each of the fins (26) extends in a common circumferential direction.
3. An aperture liner according to claim 2, wherein, at rest, each of the fins (26) extends at an angle to a tangent of the body (16) where the fin (26) is attached.
4. An aperture liner according to any preceding claim, wherein each fin (26) comprises a proximal edge (28) connected to said outer surface (20) of said body (16), an opposite distal edge (30), an upper edge (32) and a lower edge (34).
5. An aperture liner according to any preceding claim, wherein each fin (26) is substantially rectangular.
6. An aperture liner according to claim 4 or claim 5, wherein the distal edge (30) extends in a direction substantially parallel to the axis of the body (16).
7. An aperture liner according to claim 4 or claim 5, wherein the distal edge (30) extends in a direction at an angle to the axis of the body (16).
8. An aperture liner according to any of claims 4-7, wherein at least part of each lower edge (34) extends upwardly towards the upper edge (32) of the fin (26).
9. An aperture liner according to any preceding claim, wherein the fins have a length which occupies from a quarter to three quarters of the circumferential distance between the fins.
10. An aperture liner according to any preceding claim, comprising from 8 to 24 said fins (26).
11. An aperture liner according to any preceding claim, wherein the upper edge of the body (16) comprises strengthening means. -8 -
12. An aperture liner according to claim 11, wherein said strengthening means comprises a flange (18).
13. An aperture liner according to any preceding claim, wherein the liner comprises a web which extends across the hollow body (16), the web being formed from a plurality of fins (50).
14. An aperture liner according to claim 13, wherein the web includes a ring (52) at the centre of the hollow body (16).
15. An aperture liner according to claim 13 or claim 14, wherein the web is provided in the form of an insert.
16. An aperture liner according to any preceding claim, wherein the hollow body (16) is substantially cylindrical.
17. An aperture liner according to claim 13 or claim 14, wherein the hollow body (16) is in the form of a ring.
18. A method of positioning an electrical fitting (40) in an aperture (12) formed in sheet material (14), comprising inserting an aperture liner (10) according to any preceding claim into the aperture (12) with the lower edge (24) of said body (16) not protruding beyond the lower face of said sheet material (14), wherein said aperture (12) has a dimension wider than said body (16), filling the space (36) between the outer surface (20) of said body (16) and the edge of said aperture (12) with settable material (42) and thereafter inserting said electrical fitting (40) into the hollow space (46) within said body (16).
19. A method according to claim 18, wherein said electrical fitting (40) comprises a downlight (40).
20. A method according to claim 19, wherein the downlight includes spring clips (44) which, when the downlight (40) is in position, press against the upper surface (48) of the sheet material (14).