GB2608831A

GB2608831A - Wall liner system

Info

Publication number: GB2608831A
Application number: GB2110078.9A
Authority: GB
Inventors: Michael Jones Jeffrey; Smith Tom; Nicholas Purdom Hans
Original assignee: Linear Building Innovations Ltd
Current assignee: Linear Building Innovations Ltd
Priority date: 2021-07-13
Filing date: 2021-07-13
Publication date: 2023-01-18
Also published as: GB202110078D0

Abstract

A wall liner comprises a plurality of wall brackets (16) for fixing to an underlying wall, a plurality of studs (18) for fixing to the wall brackets(16), and at least one sheet of plasterboard (20) for fitting over the studs (18) to provide a cavity between a spaced wall surface and the underlying wall. The wall and wall liner define an opening, and the system provides a door (12) for extending across the opening. The system further comprises a frame fitting around the perimeter of the door (12), the frame comprising a frame member (22) having a door edge facing part (56), a perpendicular front flange (50) and a stop (60) for the door (12) to stop the door swinging through the frame. The front flange overlies a room-facing edge region of the sheet of plasterboard (20) around the opening. The system further comprises an L bracket (24) for attaching to the frame member (22) and the underlying wall, the L bracket (24) extends rearward behind the frame, whereby the frame can be attached to both the underlying wall by the L bracket (24) and to the front of the wall by the front flange (50).

Description

Wall Liner System The present invention relates to a wall liner system incorporating a door across an opening therein, and a frame around at least part of the perimeter of the door.

It is a common building practice to line a wall with a wall liner system, a practice also known as dry lining or dry walling. It installs a new plasterboard face on an underlying wall. These systems are particularly effective at correcting surface irregularities on the underlying wall, and can be installed with little or no background preparation of the underlying wall. In other words, wall liner systems can commonly be installed directly onto the underlying wall (even one with significant surface irregularities) without any need to clean the wall back to a smoother finish, save in extreme circumstances.

Typically these dry lining systems create a cavity behind the new plasterboard face between the back of the plasterboard and the underlying wall, which cavity might be infilled with insulation if desired -commonly of either (or both) a thermal or sound insulation type. The cavity can also or instead be used to accommodate service runs, such as electric wires or cabling conduits, or water or gas pipework.

Numerous wall liner systems exist for dry lining a wall. For example, there is GypLyner® by British Gypsum®, the Tradeline® Wall and Ceiling Lining System, and the Knaufe Wall Liner System. These and most other wall liner systems involve attaching a framework to the wall, generally using adjustable U brackets on the wall (commonly a folded metal strip with multiple screw holes) to space from the underlying wall a series of subsequently fitted vertical or horizontal studs (usually connected to the U brackets using self-tapping screws). The studs will typically extend parallel to one another to provide the framework that is spaced from the wall by the U brackets, that spacing defining the cavities mentioned above.

A conventional door can be fitted into a wall fitted with a wall liner system by fitting plasterboard around the opening in the wall and screwing a frame for the door to the underlying wall with long screws -either through the plasterboard that lines the opening, or directly to that underlying wall if the plasterboard is fitted after the frame, around the frame. However, some doors -particularly doors intended to be flush fitted to the level of the new plasterboard face for the room, cannot be so fitted as the wall screws, if fitted through the frame for such doors, which frames are deliberately designed to be low profile so as to enable the flush fit, would only extend into the cavity behind the plasterboard face. To remedy this, in the prior art the installers of such wall liner systems have attempted to positioned the closest stud of the wall liner system close to the opening to try to allow engagement of that stud with the wall screws for the door frame. However, this complicates the installation of the framework, and can cause uneven distribution of the studs on the wall. The present invention seeks to provide an alternative mode of installation for flush fitted doors in an opening in a wall featuring a wall liner system.

According to a first aspect of the present invention there is provided a wall liner system for incorporating a door across an opening in a wall, the wall liner system comprising: a plurality of wall brackets for fixing to an underlying wall with an opening therein; a plurality of studs for fixing to the wall brackets; at least one sheet of plasterboard for fitting over the studs to provide a spaced wall surface from the underlying wall and a cavity between the spaced wall surface and the underlying wall; a door for the opening; a frame for fitting around at least part of the perimeter of the door in the opening, the frame comprising at least one frame member having a door edge facing part, a front flange extending perpendicular thereto and a stop for the door to prevent swinging of the door through the frame when installed, the front flange being for lying over a room-facing edge region of the sheet of plasterboard situated around the opening; and at least one L bracket for attaching to the frame member and to the underlying wall, the L bracket being for extending rearward behind the frame, whereby the frame can be attached to both the underlying wall by the L bracket and to the front of the wall by the front flange.

In some embodiments the wall brackets are U brackets.

The wall brackets may be fixed to the underlying wall with fixings such as screws, preferably with an anchoring system such as a Rawlplug O. These can be hammer fittings for ease of fit.

The wall brackets may be folded lengths of metal strips, preferably with a central fixing hole and multiple side fixing holes for attachment thereof to one of the studs.

In some embodiments the studs are elongated U or C section beams. They can have a flat back for presenting a surface to which the sheet of plasterboard can be attached, for example with wall screws-which may self-tap through the flat back. The studs can have flat sides for attaching to the wall brackets.

Because the wall brackets may have multiple holes to the sides thereof, they can attach to a later installed stud using one or more self-tapping screw through an appropriate one of those holes -ones that align to, for example, one of the flat sides of the stud. By having multiple holes, and using self-tapping screws, the wall bracket can space the stud from the underlying wall at any chosen spacing, thus allowing a plurality of studs to be fitted in a flat manner even against an uneven underlying wall, as the brackets' adjustability can allow that uneven surface effectively to be flattened by the studs.

In some embodiments the wall brackets are provided in a length that is longer than needed, and after fitting of the stud, the excess ends of the wall bracket can be folded back from the backs of the studs so as not to interfere with the sheet of plasterboard.

In some embodiments the studs are fitted to end rails and are then attached to the wall brackets. The end rails may be attached to the floor or ceiling of the room, or to the underlying wall near the floor or ceiling, or to or at a lintel or threshold of the opening.

The wall liner system may comprise one or more further sheets of plasterboard for fitting in the opening between the frame and L bracket and the underlying wall. The one or more further sheets of plasterboard may extend across the cavity to a rear face of the room-facing edge region of the sheet or sheets of plasterboard for attaching to the studs, i.e. situated around the opening.

In some embodiments one or more strip of additional plasterboard is provided to bridge the cavity between the sheet or sheets of plasterboard for attaching to the studs and the underlying wall. Preferably the one or more strip of additional plasterboard backs onto the one or more further sheets of plasterboard to provide a double-thickness of plasterboard across the cavity at or adjacent to the front corners of the opening.

Preferably the front flange of the frame member attaches to the corner of the opening with a wall screw that extends through the sheet of plasterboard that attaches to the studs. More preferably that screw further extends into that double thickness of plasterboard -preferably into the strip of plasterboard.

In some embodiments, the further sheet or sheets of plasterboard are a fire resistant form of plasterboard. Likewise, preferably, the strip of plasterboard is a fire resistant form of plasterboard.

In some embodiments, the door is infilled with a infill material. In some embodiments the door is a fire-rated fire door, and the infill material is a heat resistant material. In some embodiments the door is a certified fire or smoke door, certified, for example, to FD30, FD3OS, FD60, FD6OS, FD90, FD9OS, FD120, FD120S in the United Kingdom, or E30, E3Osa, E60, E60Sa, E90, E90Sa, E120 and E120Sa in Europe, tested to the relevant Standard, for example to BSEN1634-land/or BSEN1634-3, or to equivalent alternative national or regional Standards.

In some embodiments, the door will be a smoke control vent.

In some embodiments, the door has front and back metal faces, a metal surrounding edge, and an infill material that is a fire resistant or fire retardant material, such as rock wool, mineral wall or a phenolic resin foam.

In some embodiments, the door is fitted in the frame flush with a front-most part of the frame member. In some embodiments, the front-most part of the frame member is a plasterers bead, formed as a forward-facing projection between the door edge facing part of the frame member and the front flange of the frame member.

In some embodiments, the stop for the door is located to hold the door, in its closed state, with a rear surface of the door lying in a plane that lies forwards of the front most plane of the underlying wall.

In some embodiments, the stop is part of a box like structure of the frame member, the box like structure being positioned either in front of or overlying the front most plane of the underlying wall.

In some embodiments, the L bracket is for attaching to a rearmost element of the frame member. The attachment may be with a self-tapping screw.

In some embodiments, the box like structure of the frame member provides the rearmost element of the frame member.

In some embodiments, the L bracket is attached to the underlying wall with a wall screw through a leg of the L bracket. In some embodiments the wall screw extends through the further sheet of plasterboard before extending into the underlying wall.

In some embodiments, the frame is formed from three or more frame members. In some embodiments the frame members have a common cross section. In some embodiments the frame members are joined at their mutual corners to form the frame. In some embodiments, the joint includes a corner bracket to reinforce the corners. The corner bracket may be attached to the frame members with screws, rivets or welds.

In some embodiments, the frame members are made of folded metal sheets.

In some embodiments, the L bracket is made of metal.

In some embodiments, the front flange of the or each frame member has apertures or a roughened surface to improve plaster adhesion thereto, the front surface of the sheets of plasterboard attached to the studs being skimmed with plaster to provide a wall surface for decorating with paint or wall paper.

The present invention also provides a method of incorporating a door across an opening in a wall, the wall comprising a wall liner system fitted on an underlying wall, the wall liner system comprising: a wall liner consisting of a plurality of wall brackets, a plurality of studs, and plasterboard; a door; a frame comprising at least one frame member having a door edge facing part, a front flange extending perpendicular thereto and a stop for the door; and at least one L bracket; wherein the method comprises a) fixing the plurality of wall brackets to the underlying wall; b) fixing the plurality of studs to the wall brackets; c) fitting at least one sheet of plasterboard over the studs, cut as needed around the opening, to provide a spaced wall surface from the underlying wall and a cavity between the spaced wall surface and the underlying wall, and a room-facing edge region for the sheet of plasterboard situated around the opening; d) fitting the at least one frame member around at least part of the opening such that the door edge facing part or parts define a space for accommodating the door therein, and such that the front flange or flanges of the or each frame member is fitted over the room-facing edge region of the sheet of plasterboard situated around the opening, and such that the stop for the door will prevent swinging of the door through the frame when installed; e) fitting the door into the space for accommodating the door in front of the stop or stops; and f) fitting the at least one L bracket to the rear of the frame and to the underlying wall to secure the frame, and thus the door therein, to the underlying wall, whereby the frame is attached to both the underlying wall by the L bracket and to the wall liner by the front flange.

In some embodiments the wall liner system is the wall liner system as defined in respect of the first aspect of the present invention. As such: The wall brackets may be fixed to the underlying wall with fixings such as screws, preferably with an anchoring system such as a Rawlplug 0. These can be hammer fittings for ease of fit.

In some embodiments, the studs are elongated U or C section beams. They can have a flat back for presenting a surface to which the sheet of plasterboard is attached, for example with wall screws-which may self-tap through the flat back. The studs can have flat sides. They can be attached to the wall brackets also with self-tapping screws.

Because the wall brackets may have multiple holes to the sides thereof, they can attach to a later installed stud using one or more self-tapping screw through an appropriate one of those holes -ones that align to, for example, one of the flat sides of the stud. By having multiple holes, and using self-tapping screws, the wall bracket can space the stud from the underlying wall at any chosen spacing, thus allowing a plurality of studs to be fitted in a flat manner even against an uneven underlying wall, as the brackets' adjustability can allow that uneven surface to effectively be flattened by the studs.

In some embodiments, the wall brackets are provided in a length that is longer than needed, and after fitting of the stud, the excess ends of the wall bracket are folded back from the backs of the studs, or are trimmed off, so as not to interfere with the sheet of plasterboard. In some embodiments either or both ends are folded to lay flush with the sides of the U bracket.

In some embodiments, the studs are fitted to end rails and are then attached to the wall brackets. The end rails may be attached to the floor or ceiling of the room, or to the underlying wall near the floor or ceiling, or to or at a lintel or threshold of the opening.

The method may comprise installing one or more further sheets of plasterboard in the opening between the combination of the frame and the L bracket and the underlying wall.

The one or more further sheets of plasterboard may extend across the cavity to a rear face of the room-facing edge region of the front sheet or sheets of plasterboard.

In some embodiments, one or more strip of additional plasterboard is provided to bridge the cavity between the front sheet or sheets of plasterboard and the underlying wall.

Preferably the one or more strip of additional plasterboard backs onto the one or more further sheets of plasterboard to provide a double-thickness of plasterboard across the cavity at or adjacent to the front corners of the opening.

Preferably the front flange of the frame member attaches to the corner of the opening -over the room-facing edge region of the sheet of plasterboard situated around the opening, with a wall screw. More preferably that screw further extends into the double thickness of plasterboard -preferably into the strip of plasterboard.

In some embodiments the door is a fire-rated fire door, and its infill material is a heat resistant material. In some embodiments the door is a certified fire or smoke door, certified, for example, to FD30, FD30S, FD60, FD6OS, FD90, FD90S, FD120, FD120S in the United Kingdom, or E30, E3Osa, E60, E60Sa, E90, E90Sa, E120 and E120Sa in Europe, tested to the relevant Standard, for example to BSEN1634-1and/or BSEN1634- 3, or to equivalent alternative national or regional Standards.

In some embodiments, the door will be a smoke control vent.

In some embodiments, the door is fitted in the frame flush with a front-most part of the frame member, or recessed therefrom by no more than 5mm. In some embodiments, the front-most part of the frame member is a plasterers bead, formed as a forward-facing projection between the door edge facing part of the frame member and the front flange of the frame member.

In some embodiments, the L bracket is attached to a rearmost element of the frame member. The attachment may be with a self-tapping screw.

In some embodiments, the frame is formed from three or more frame members. In some embodiments the frame members have a common cross section. In some embodiments the frame members are joined at their mutual corners to form the frame. In some embodiments the joint includes a corner bracket to reinforce the corners. The corner bracket may be attached to the frame members with screws, rivets or welds. The L brackets are typically positioned so as not to overlie the corner brackets, but may be immediately adjacent ends of those corner brackets.

In some embodiments, the frame members are made of folded metal sheets.

In some embodiments, the L bracket is made of metal.

In some embodiments, the front flange of the or each frame member has apertures or a roughened surface to improve plaster adhesion thereto, the front surface of the sheets of plasterboard attached to the studs being skimmed with plaster to provide a wall surface for decorating with paint, wall paper, or other wall coverings.

The present invention will now be described in further detail, purely by way of example, by reference to the accompanying drawings, in which: Figure 1 is a front view of an opening in a wall fitted with the wall liner system of the present invention, absent final plasterboard sheeting; Figure 2 is a top-down section through the opening in the wall of Figure 1, with the final plasterboard sheeting shown on the walls; Figure 3 is an enlarged view of area A in Figure 2; Figure 4 is an enlarged view of area A in Figure 3; Figure 5 is a sideward section through the opening in the wall of Figure 1, with the final plasterboard sheeting shown on the walls; Figure 6 is an enlarged view of area C in Figure 5; Figures 7 to 10 show an L bracket as used in the present invention; and Figure 11 shows a perspective view of a bottom corner of a door fitted in accordance with the method of the present invention, showing L brackets screwed to the underlying wall and the frame for the door.

Referring to Figures 1 to 3, an installation of a door 12 across an opening in a wall 14 is shown. It features a wall liner system 10 of the present invention, including a plurality of U brackets 16, a plurality of studs 18, at least one sheet of plasterboard 20, at least one frame member 22, at least one L bracket and fixings, such as screws 26, 28, 30, 36, 52, 94.

As per prior art wall liner systems, this wall liner system 10 involves attaching a framework to the wall, using multiple adjustable U brackets 16 on the wall 14 (here the U bracket is a folded metal strip with a hole for a screw for attaching it to the wall 14 with a first screw -U bracket screw 28, and multiple screw holes to the sides thereof for attaching it to a later installed stud 18 using self-tapping screws 30. By having multiple holes, and using self-tapping screws, the U bracket can space the stud 18 from the underlying wall 14 and affix the stud 18 to U bracket 16 irrespective of the size of the spacing as the self-tapping screw will tap its own hole into the stud. As shown in Figure 3, any spare free end or waste 32 of the U bracket can then be folded to avoid it extending beyond the stud 18. In Figure 4, the other free end 32 can be seen to be folded back on itself.

Once the U brackets 16 and the studs 18 are installed, they will form a framework with the studs 18 typically extending parallel to one another -here vertically -to provide the framework that is spaced from the wall by the U brackets.

As known in the art, perpendicular bracings 34 (or noggins -not shown) can also be fitted between the studs, for example to surround openings in the wall, such as windows, or to strengthen the framework, or in this case to provide part of a lintel at the top of the door.

As known in the art, cross beams or end rails (not shown) may be provided across the ends of the studs 18 -or more usually the cross beams or end rails will be fitted before the studs 18, e.g. at the floor and ceiling, so that the studs 18 can be fitted between them to align the studs into a common plane, so that the studs can then be fixed to the U brackets using the self-tapping screws 30 discussed above, to lock the resulting framework in place.

The U brackets 16 can then be trimmed to length (or folded back) to leave a front surface of the studs 18 for receiving the plasterboard 20. The plasterboard 20 can thus then be fitted onto the studs in the conventional manner -typically using screws (not shown) to provide a new and flat wall surface for decorating.

Depending upon the size of the standoff needed from the original wall -usually dictated by the flatness of the underlying wall, or the size of the cavity required (e.g. to accommodate a specified insulation thickness), different sized U brackets 16 can be used to reduce the lengths of the free ends 32. Also, the U brackets 16, by having the multiple screw holes in the sides thereof, are themselves adjustable to accommodate different cavity thicknesses. They thus allow the studs 18 to be installed parallel to one another, irrespective of the flatness of the underlying wall, as the studs can be affixed to the U brackets 16 with the self-tapping screws 30 at whatever position they adopt relative thereto, for achieving a reliably flat surface from the parallel studs 18 facing into the room.

The studs 18 are commonly each a U or C sectioned beam that bridges across multiple U brackets 16 on the wall 14 -in this example, multiple vertically spaced U brackets 16.

The studs 18 typically extend between cross beams or end rails (when provided) with their backs facing into the room -the open front of the U or C instead faces the wall. Those backs then present a flat plasterboard-receiving surface. The U brackets 16 on the other hand have their backs against the wall, and the open front facing into the room.

Once the studs 18 are in place to form the framework, the plasterboard 20 can then be fitted to the backs of the studs, usually simply by using self-tapping screws 30 -one on each sidewall of the U brackets 16 and studs 18. The plasterboard 20 then presents a flat wall surface for the room that covers any surface irregularities in the original wall surface. Figures 2 and 3 both show the plasterboard 20 overlying the rails and Figure 3 shows a plasterboard screw 36 that has self-tapped into the back 38 of the stud 18.

Referring back to Figure 1, multiple courses of blockwork are shown to form the wall 14, with mortar lines 46 extending horizontally between the courses, and vertically between the blocks 44 within each course of blocks 44. These blocks may be 14omm lightweight Celcon ®, bricks or other building blocks used in the constructions of the building. It could even be a concrete wall or stonework.

In this illustrated embodiment, the blocks down each side of an opening 42 in the wall 14 have substantially aligned free ends, which together define the sides of the opening 42. A lintel supports the blocks at the top of the opening, and the blocks at the bottom form the bottom of the opening. This opening 42 is therefore substantially rectangular.

Referring back again to Figures 2 and 3, a further plasterboard 40 is shown lying perpendicular to the plasterboard sheet 20 on the studs 18. It is provided against the free ends of the blocks down each side of the opening 42 to line the opening 42 in the wall 14. The further plasterboard 40 can but against the inside face of the plasterboard sheet 20 on the studs 18.

Referring next to Figure 3, a strip 46 of plasterboard is cut to bridge a cavity 48 behind the plasterboard sheet 20 on the studs 18. That strip 46 of plasterboard can back the further plasterboard 40 to present a double thickness, or two layer, portion of plasterboard in that area to help secure the framing of the opening 42. Also, in the case of the invention being used to install a smoke vent, or a fire door, this strip 46, along with the further plasterboard 40, can be made of a fire resistant plasterboard, such as Knauf Firepanel TE and the double thickness helps to better seal the cavity 48 from the opening 42.

Referring next to Figure 4, an enlarged view of this area of the invention is shown. As can be seen there is the further plasterboard 40 against the wall 14, and the strip 46 of plasterboard between the front (room facing) plasterboard sheet 20 and the wall, bridging across the cavity 48 to provide the double layer of plasterboard (the strip 46 and the further plasterboard 40). That double layer of plasterboard also serves to support the mounting of a frame member 22 to the opening 42. For that purpose, the frame member 22 has a flange 50 that is arranged against the room facing side of the plasterboard sheet 20. That flange 50 may be perforated by a series of holes, or otherwise surface roughened, to assist with the adhesion of plaster thereto, as it will typically be a metal component (usually galvanised or stainless steel). Through that flange -e.g. through one of the holes, or through a hole provided specifically for this purpose, a wall screw 52 is driven to extend through one of the two layers of plasterboard that forms the double later mentioned above. In this embodiment, it is the strip 46 of plasterboard that receives that wall screw 52. That screw 52 ideally extends to engage with the blockwork of the wall 14, although that is optional. As that wall screw engages the double thickness layer of plasterboard, along with the front facing sheet of plasterboard, and since the strip of plasterboard bears against the wall 14, the wall screw can provide a strong retention of the frame member 22 over the underlying corner of plasterboard (where the sheets 20, 40 meet). If there was just a single layer of plasterboard, then the corner would be less strong. The strip of plasterboard therefore provides a useful strengthening role.

In this embodiment, the strip of plasterboard backs onto the folded back part of the free end 32 of the U bracket. It is thus additionally supported by those brackets, further enhancing the strength of the front corner of the opening.

The frame member 22 further has a plastering bead 54 formed in it to provide a guide for a plasterer -so that the wall can be correctly finished around the opening by a skim of plaster over the flange 50 and the plasterboard sheet 20 on the studs 18. Such a skim of plaster is commonly applied with wall liner systems, and the frame member's design is helpful for this purpose. In a conventional door frame, the frame would not extend over the front corner of the opening as the door would be recessed back from the front face of the front plasterboard 20. In this invention, however, we are providing a flush fit door arrangement, as will be discussed below, so this frame member 22 has these beneficial features.

The frame member 22 then folds backwards across the face of the further plasterboard 40 to provide a return section 56 that extends at least partially across the depth of the cavity 48. That return section 56 extends to a further bend 58 in the frame member 22, which further bend forms door stop component 60 of the frame member 22 that extends partially across the opening -by perhaps 10 to 25mm.

That door stop component 60 can be part of a box section of the frame member 22, or as shown, can be part of a partial box section. In this embodiment the partial box section has a door-engaging part 70 that provides a door facing face for providing the stop's primary function of stopping the door 12 from swinging through the frame (formed from one or more frame member 22 that extends around the opening 42), a laterally extending inner part 62 that continues the extension of the frame member 22 across the depth of the cavity 48, a rear part 64, and a return part 66 that extends from a fourth corner of the box. In this embodiment, the four parts 62, 64, 66, 70 of the box define a generally rectangular shape, with approximately right-angled corners.

The frame member 22 is preferably formed as a folded metal member, with the folds extending along the length of the frame member 22.

A rear of the frame member 22 provides a receiving surface 68 for an L bracket 24. In this embodiment the receiving surface 68 is formed as the rear face of the rear part 64 of the box.

The frame member 22 is also provided with a door seal 72. This seal 72, which may be a rubber extrusion, or some other form of smoke or draught seal, fits between the door 12 and the frame member 22 so that when the door is closed, the seal is active. Such a seal is generally important where the door is a fire door, or part of a smoke control system of the building. In this embodiment, Figure 4 shows the door to be infilled with a infill material. For a fire door this may be a heat resistant material. Typically, the door will be a smoke control door, and as such it may have front and back metal faces, a metal surrounding edge, and the infill material may be a fire resistant or fire retardant material, such as rock wool, mineral wall or a phenolic resin foam.

Returning to the L bracket discussed above, it is provided to allow the frame member 22 to be used in the present invention's installation. With the frame member 22 being arranged over a front corner of the opening, and since the frame member 22 only just extends further rearward from that front corner than the cavity 48, due to the door being arranged to sit flush with a front element (in this embodiment the plastering bead 54) of the frame member 22, the convention of affixing the frame member to the wall with a screw won't work unless the installer is skilful enough to achieve an engagement of the usual wall screw (through a hole 74 in the frame member 22, such as through the stop 60 or the return section 56) with the U bracket or stud. Further, even if the installer can achieve such an engagement, for that engagement to be in the stud would not be ideal as the stud would gradually deteriorate if the door was to be opened and closed, as the stud is a relatively light gauge of steel to allow it to be self-tapped by the screws 36. Likewise, such an engagement with the U bracket would not be ideal as it would add to the possibility of damaging the mounting of that U bracket to the wall, and furthermore since the U bracket may be too heavy a gauge of steel for such a screw mounting of the frame to achieve penetration of the U bracket's material. Together, therefore, it is difficult to mount the frame member to the wall and wall liner system, other than through the flange 50 and into the double thickness of plaster. The frame member 22 is thus currently only poorly mounted in the opening.

With the L bracket, however, a further attachment of the frame member 22 to wall becomes possible. The L bracket provides a foot and a leg component, with the leg providing an extension to the frame member 22 to extend the position of mounting thereof into a position that suitably overlies the underlying blockwork of the wall 14. The foot on the other hand attaches to the frame member 22 by way of a self-tapping screw 30 -into the rear receiving surface 68 of the frame member 22.

Thus, with the L bracket a wall screw 94 can be used to affix the frame firmly in the opening as it will engage into the blockwork, rather than just the plasterboard (or tentatively additionally with the stud or U bracket).

As shown the further wall screw 94 extends through the leg of the L bracket and also through the further plasterboard 40 and into the blockwork 44 of the wall 14.

Typically multiple L brackets will be used -at least two on the uprights of the frame, although preferably at least three, and likely at least two also at the top of the frame, and possibly at least two at the bottom of the frame.

This invention is particularly suitable for doors covering over ventilation openings in a wall such as for part of a smoke control system of a building as the rear of the opening will not be facing into an occupied part of the building, but instead into a ventilation shaft or ventilation chimney/passageway of the smoke control system. As such the unfinished appearance of the L brackets would not be problematic for the overall aesthetics of the installation. Instead, only the front of the opening need be finished, and the flush fitting nature of the door in the frame, along with the flush fitting of the frame member over the front corner of the opening, in addition to the plastering bead in the frame member 22 for the room facing plasterboard 20, allows a lean and flush installation to be achieved.

Referring next to Figures 5 and 6, the application of the present invention to a bottom edge of a door 12 is shown, albeit not a door with a ground-level threshold, but instead with a threshold raised above ground level. This is a common scenario for a smoke vent door -a type of door for which the present invention is particularly suited.

Referring to Figure 6, the arrangement is largely the same as in Figure 4, although the studs 18 extend perpendicular to the bottom of the door, and thus cannot be seen as C or U sections. In this example, the ends of the studs 18 fit in tracks -one of which is fitted to the ground level 78 and the other is fitted under the double thickness of plasterboard 40, 44, and these tracks 76 extend as cross beams or end rails for the studs 18, as discussed above for the ends of the rails 18.

In this example, the wall screw 30 for affixing the frame member 22 to the plasterboard sheet 20 at the front of the framework extends underneath the strip of plasterboard, which is also acceptable versus the arrangement shown in Figures 3 and 4.

In this example, the stop is still provided for the frame member at the bottom of the door as the door will need to seal around the full perimeter thereof as it is a door for resisting smoke transmission through the opening.

Referring next to Figures 7 to 10, various views of the L bracket 24 are provided. As can be seen the L bracket 24 has a leg component 80 and a foot component 82, arranged perpendicular to one another. In this example, the leg has two slots 84 arranged parallel to the longitudinal length of the leg 80. These slots allow a wall screw 94 to be fitted to the L bracket in a variety of positions, and can allow some adjustment after installation by loosening the screw 94. Similarly, the foot 82 has two parallel slots 86 that extend along the longitudinal direction of the foot 82 which likewise allow some latitude on the positioning of the self-tapping screw 30 and for adjustment by loosening the screw 30.

Referring finally to Figure 11, a perspective of a bottom corner of the installation is shown.

In this example, in place of the slots 86 in the feet 82, holes are provided, although they are covered by the self-tapping screws 30.

Figure 11 also shows a corner bracket for joining adjacent frame members 22 in the corners of the frame. The corner bracket is optional but it serves to reinforce the corners, which can help keep the frame square during installation, thus reducing difficulties with the door skewing relative to the frame. A similar corner bracket can be fitted in each of the four corners of this rectangular frame.

Figure 11 also shows the shoot bolt 90 for locking the door in a closed state, as also visible in Figures 5 and 6. This shoot bolt can be operated via a handle so as to extend and retract into a hole in the frame -sliding for that purpose through a mounting bracket 92. Such shoot bolts are a common feature in multipoint locking systems for doors.

The present invention has therefore been described above purely by way of example.

Modifications in detail may be made to the invention within the scope of the claims as appended hereto.

Claims

CLAIMS: 1. A wall liner system for incorporating a door across an opening in a wall, the wall liner system comprising: a plurality of wall brackets for fixing to an underlying wall with an opening therein; a plurality of studs for fixing to the wall brackets; at least one sheet of plasterboard for fitting over the studs to provide a spaced wall surface from the underlying wall and a cavity between the spaced wall surface and the underlying wall; a door for the opening; a frame for fitting around at least part of the perimeter of the door in the opening, the frame comprising at least one frame member having a door edge facing part, a front flange extending perpendicular thereto and a stop for the door to prevent swinging of the door through the frame when installed, the front flange being for lying over a room-facing edge region of the sheet of plasterboard situated around the opening; and at least one L bracket for attaching to the frame member and to the underlying wall, the L bracket being for extending rearward behind the frame, whereby the frame can be attached to both the underlying wall by the L bracket and to the front of the wall by the front flange.
2. The wall liner system of claim 1, wherein the wall brackets are folded lengths of metal strips, with a central fixing hole and multiple side fixing holes for attachment thereof to one of the studs.
3. The wall liner system of claim 1 or claim 2, wherein the studs have a flat back for presenting a surface to which the sheet of plasterboard can be attached.
4. The wall liner system of any preceding claim, further comprising one or more further sheet of plasterboard for fitting in the opening between the frame and L bracket and the underlying wall.
5. The wall liner system of claim 4, wherein the one or more further sheet of plasterboard extends across the cavity to a rear face of the room-facing edge region of the sheet or sheets of plasterboard.
6. The wall liner system of any one of the preceding claims, wherein one or more strip of additional plasterboard is provided to bridge the cavity between the sheet or sheets of plasterboard for attaching to the studs and the underlying wall.
7. The wall liner system of claim 6, further being in accordance with claim 4, wherein the one or more strip of additional plasterboard is provided to back onto the one or more further sheet of plasterboard to provide a double-thickness of plasterboard across the cavity at or adjacent to the front corners of the opening.
8. The wall liner system of claim 7 wherein the further sheet or sheets of plasterboard and the strip of plasterboard are a fire resistant form of plasterboard.
9. The wall liner system of any one of the preceding claims, wherein the door is a fire-rated fire door, and the door has an infill material that is a heat resistant material.
10. The wall liner system of any one of the preceding claims, wherein the door is a smoke control vent.
11. The wall liner system of any one of the preceding claims, wherein the door has front and back metal faces, a metal surrounding edge, and an infill material that is a fire resistant or fire retardant material, such as rock wool, mineral wall or a phenolic resin foam.
12. The wall liner system of any one of the preceding claims, wherein the frame is formed from three or more frame members.
13. The wall liner system of claim 12, wherein the frame members have a common cross section.
14. The wall liner system of any one of the preceding claims, wherein the frame member is made of a folded metal sheet.
15. The wall liner system of any one of the preceding claims, wherein the L bracket is made of metal.
16. The wall liner system of any one of the preceding claims, wherein the front flange of the or each frame member has apertures or a roughened surface to improve plaster adhesion thereto.
17. A method of incorporating a door across an opening in a wall, the wall comprising a wall liner system fitted on an underlying wall, the wall liner system comprising: a wall liner consisting of a plurality of wall brackets, a plurality of studs, and plasterboard; a door; a frame comprising at least one frame member having a door edge facing part, a front flange extending perpendicular thereto and a stop for the door; and at least one L bracket; wherein the method comprises g) fixing the plurality of wall brackets to the underlying wall; h) fixing the plurality of studs to the wall brackets; i) fitting at least one sheet of plasterboard over the studs, cut as needed around the opening, to provide a spaced wall surface from the underlying wall and a cavity between the spaced wall surface and the underlying wall, and a room-facing edge region for the sheet of plasterboard situated around the opening; j) fitting the at least one frame member around at least part of the opening such that the door edge facing part or parts define a space for accommodating the door therein, and such that the front flange or flanges of the or each frame member is fitted over the room-facing edge region of the sheet of plasterboard situated around the opening, and such that the stop for the door will prevent swinging of the door through the frame when installed; k) fitting the door into the space for accommodating the door in front of the stop or stops; and I) fitting the at least one L bracket to the rear of the frame and to the underlying wall to secure the frame, and thus the door therein, to the underlying wall, whereby the frame is attached to both the underlying wall by the L bracket and to the wall liner by the front flange.
18. The method of claim 17, wherein the wall liner system is the wall liner system is in accordance with any one of claims 1 to 16
19. The method of claim 17 or claim 18, wherein the studs are fitted to end rails and are then attached to the wall brackets.
20. The method of any one of claims 17 to 19, further comprising installing one or more further sheets of plasterboard in the opening between the combination of the frame and the L bracket and the underlying wall.
21. The method of any one of claims 17 to 20, further comprising installing one or more strip of additional plasterboard to bridge the cavity between the front sheet or sheets of plasterboard and the underlying wall.
22. The method of claim 21, wherein the one or more strip of additional plasterboard backs onto the one or more further sheets of plasterboard of claim 20 to provide a double-thickness of plasterboard across the cavity at or adjacent to the front corners of the opening.
23. The method of any one of claims 17 to 22, wherein the front flange of the frame member attaches to the corner of the opening over the room-facing edge region of the sheet of plasterboard situated around the opening, with a wall screw.
24. The method of any one of claims 17 to 23, wherein the door is fitted in the frame flush with a front-most part of the frame member, or recessed therefrom by no more than 5mm.
25. The method of any one of claims 17 to 24, wherein a front-most part of the frame member is a plasterers bead, formed as a forward-facing projection between the door edge facing part of the frame member and the front flange of the frame member.
26. The method of any one of claims 17 to 25, wherein the stop for the door is located to hold the door, in its closed state, with a rear surface of the door lying in a plane that lies forwards of the front most plane of the underlying wall.
27. The method of any one of claims 17 to 26, wherein the stop is part of a box like structure of the frame member, the box like structure being positioned either in front of or overlying the front most plane of the underlying wall.
28. The method of any one of claims 17 to 27, wherein the L bracket is attached to a rearmost element of the frame member.
29. The method of any one of claims 17 to 28, wherein the L bracket is attached to the underlying wall with a wall screw through a leg of the L bracket.
30. The method of any one of claims 17 to 29, wherein the frame is formed from three or more frame members that have a common cross section, and the frame members are joined at their mutual corners to form the frame by a corner bracket to reinforce the corners.
31. The method of any one of claims 17 to 30, wherein the front flange of the or each frame member has apertures or a roughened surface to improve plaster adhesion thereto, the front surface of the sheets of plasterboard attached to the studs being skimmed with plaster to provide a wall surface for decorating with paint or wall paper.