US20200340248A1

US20200340248A1 - Face mount inserts

Info

Publication number: US20200340248A1
Application number: US16/762,077
Authority: US
Inventors: Brian Leonard Moore; Christopher Charles Morrow
Original assignee: Teclite Industries Ltd
Current assignee: Teclite Industries Ltd
Priority date: 2017-12-05
Filing date: 2018-12-05
Publication date: 2020-10-29
Also published as: GB2583033A8; CA3082969A1; WO2019111163A1; AU2018378299A1; GB2583033A; GB202008499D0

Abstract

This invention relates to an insert component to be affixed to a panel. The insert component comprises a body, the body including a first face and a second face, the body defining at least one opening extending between the first face and the second face, said at least one opening positioned within a perimeter of the body. A flange portion extends substantially radially outwardly from one or each of said at least one opening. At least one rim is provided upon said first face and substantially about a perimeter of each said opening. At least one channel region is provided in said first face and substantially about the perimeter of each said opening, said channel region located outwardly of said rim relative to said perimeter of each said opening.

Description

FIELD OF THE INVENTION

The present invention relates to a component which can be affixed to a panel or affixed into a rebate of a panel, the component providing for a structural support for an item to be located within an aperture of said panel, or relates to an insert for altering the shape or size of an existing aperture through a panel, more particularly, though not solely, to a pre-form to be used as an insert into an existing aperture through a building panel.

BACKGROUND TO THE INVENTION

Various solutions have been proposed for reducing the size of an aperture through a panel, such as a ceiling or wall panel. In particular, problems exist where for example an existing aperture of a certain size has been made to accommodate, say a lighting fixture or a conduit to pass through the panel, but then that fixture or conduit is to be replaced with a smaller size which no longer needs the existing aperture size.
Indeed, where the aperture size for the replacement fixture or conduit or any other such device extending through an aperture is smaller than the existing aperture, there becomes a problem as to how to adequately reduce the aperture whilst also ameliorating the gap between the existing aperture side wall and the size of the device to extending through the panel.
Typically, an existing aperture may be in-filled by using a piece or pieces of the same (or different) panel material. However, the jointed region between such in-fill materials and the panel itself may be weak or may weaken or fail over time. For example, where there is an existing circular aperture through a ceiling panel and that existing aperture is to be reduced in size, an annular ring of material may be cut to be inserted into the existing aperture to provide the new aperture size. The joint between the outer surface of the annular ring and the panel may be connected to each other using joint tapes and layers of concealing material (e.g. plaster). However, such a solution still presents problems as the joint region may fail or weaken, leading to problems of cracked concealing material (plaster) or other finishing materials (e.g. paints).
In this specification where reference has been made to patent specifications, other external documents, or other sources of information, this is generally for the purpose of providing a context for discussing the features of the invention. Unless specifically stated otherwise, reference to such external documents is not to be construed as an admission that such documents, or such sources of information, in any jurisdiction, are prior art, or form part of the common general knowledge in the art.
Further aspects and advantages of the present invention will become apparent from the ensuing description which is given by way of example only.

SUMMARY OF THE INVENTION

It may therefore be an object of the present invention to provide for an insert component to be affixed to a panel to provide for a support structure about an aperture through said panel and/or which will go at least some way towards addressing the foregoing problems or which will at least provide the public with a useful choice. Such an insert is configured to receive or locate an item, such as a light fitting or fixture, or another item as may be described in this specification. It will be appreciated other items may be supported by the insert component as disclosed in this specification and need not be limited to those items which are specifically disclosed herein.
It may also be an object of the present invention to provide for an insert component capable of altering the shape and/or size of an existing aperture through a panel and/or which will go at least some way towards addressing the foregoing problems or which will at least provide the public with a useful choice.
In a first aspect there is provided an insert component to be affixed to a panel, said insert component comprising:
a body, the body including a first face and a second face, the body defining at least one opening extending between the first face and the second face, said at least one opening positioned within a perimeter of the body,
a flange portion extending substantially radially outwardly from one or each of said at least one opening, and
at least one first rim provided upon said first face and substantially about a perimeter of each said opening, and at least one second rim provided upon said first face and substantially about the perimeter of each said opening, wherein said first rim is located outwardly of said second rim relative to said perimeter of each said opening,
and wherein each of said first rim and said second rim are spaced from each other to define a channel region.
Each of said first rim and said second rim may be projections extending upwardly or away from said first face.
Each of said first rim and said second rim may be provided as projections upstanding from said first face.
The first rim may be of a first rim height relative to a first face surface of said flange portion, and said second rim may be of a second rim height relative to a first face surface of said flange portion.
The first rim height may be substantially equal to or less than said second rim height.
The second rim height may be substantially equal to or greater than said first rim height.
The first rim height may be less than said second rim height.
A height of the first rim may be about 1 mm, or about 2 mm, or about 3 mm, or about 4 mm, or about 5 mm, or about 6 mm, or about 7 mm, or about 8 mm, or about 9 mm, or about 10 mm, or may be less than about 10 mm, or less than about 8 mm, or less than about 6 mm, or less than about 4 mm, or less than about 2 mm, as measured from said first face of said body.
A height of the second rim may be about 2 mm, or about 3 mm, or about 4 mm, or about 5 mm, or about 6 mm, or about 7 mm, or about 8 mm, or about 9 mm, or about 10 mm, or about 11 mm, or about 12 mm, or may be less than about 12 mm, or less than about 10 mm, or less than about 8 mm, or less than about 6 mm, or less than about 4 mm, or less than about 2 mm, as measured from said first face of said body.
The channel region may have a floor or base defining a channel region depth, said floor or base being of a level, or providing for floor or base sections of a level, which may be one or more of:

- a level substantially equal to said first surface of said flange portion,
- a level substantially lower than said first surface of said flange portion,
- a level substantially higher than said first surface of said flange portion.

The channel may be of a pre-determined width, said width defined between facing side walls of each of said first rim and said second rim.
Said width may be sufficient to accommodate or receive a (curable) material.
The channel may be of a width that is greater than about 1 mm, or greater than about 2 mm, or greater than about 3 mm, or greater than about 4 mm, or greater than about 5 mm, or greater than about 10 mm, or greater than about 15 mm, or may be about 2 mm, or may be about 3 mm, or may be about 4 mm, or may be about 5 mm, or may be about 6 mm, or may be about 8 mm, or may be about 10 mm, or may be less than 10 mm.
The material may be a filler material (such as, but not limited to, one or more of: a plaster-type or render-type material, such as a material comprising of gypsum, lime or cement material, or is a material capable of being decorated or may be a material which can be finished, e.g. can be sanded to a finished surface, for a subsequent application of a decorative material, such as paint).
One or more of said at least one opening may further comprises of a ledge, said ledge providing a support surface extending substantially inwardly toward a centre of said opening.
The support surface may be a surface facing the same direction as said first face of said body.
The support surface may be a substantially planar surface.
The support surface may provide a surface upon which an item is seatable.
The item may be a light fixture or fitting, or may be a smoke alarm or smoke detector or other fittings or fixtures.
One or more projections may be provided upon said second face of said body.
The projections upon said second face of said body may extend a pre-determined height or distance away from said second face.
The projections upon said second face may be provided to, in-use, space said body, via said second face, away from a surface upon which said second face is to be located.
The projections upon said second face may be provided to, in-use, provide a gap or a space between said second face and a surface upon which said second face is to be located.
The space or gap may provide a void into which a (optionally curable) material can be in-filled.
The one or more projections may be provided upon said second face of said body are distributed about said second face.
The one or more projections may be provided upon said second face of said body are distributed substantially evenly or equidistantly from each other and about said second face.
There may be six projections provided upon said second face of said body.
The projections upon the second face may be of a pre-determined height or extend a distance away from the second face of about 0.5 mm, or about 1 mm, or may be less than about 5 mm, or less than about 4 mm, or less than about 3 mm, or less than about 2 mm, or less than about 1 mm, or less than about 0.5 mm.
The flange may extend substantially about a part, or parts, or substantially an entirety, of said perimeter of said body.
The flange may extend as two opposing sides of said body (i.e. there are cut-off or straight side portions).
The flange may comprise one or more apertures, said apertures extending through said body.
The apertures may provide for a void through said body.
The apertures may be distributed about said flange.
The second face of said body may be a substantially planar surface.
The second face of said body may be substantially planar, apart from one or more projections provided upon said second face of said body.
The body may be substantially circular, oval or of a rectilinear perimeter shape.
One or more of said at least one opening(s) may be substantially circular, oval or of a rectilinear perimeter shape.
The ledge may be substantially circular, oval or of a rectilinear perimeter shape.
A diameter of an inner perimeter of said second rim may be about 25 mm to about 104 mm, or may be about 76 mm, or may be about 86 mm, or about 102 mm, or about 103 mm, or about 104 mm, or about 105 mm, or about 106 mm, or may be about 160 mm, or may be about 200 mm, or may be greater than about 10 mm, or greater than about 20 mm, or greater than about 25 mm, or greater than about 30 mm, or greater than about 35 mm, or greater than about 40 mm, or greater than about 50 mm, or greater than about 85 mm, or greater than about 100 mm, or greater than about 105 mm, or greater than about 125 mm, or greater than about 150 mm, or greater than about 175 mm, or greater than about 200 mm, or greater than about 300 mm, or greater than about 400 mm.
The flange may be detachable or attachable or integral with said body.
The first rim or said second rim, or both, may be detachable or attachable or with said body.
The ledge may be detachable or attachable or integral with said body.
The projections provided upon said second face of said body may detachable or attachable or integral with said body.
A separate component piece, such as a plate-type component piece, may be provided for seating upon the ledge.
The separate component piece may be provided as a plate-type component piece comprising of one or more apertures.
The separate component piece may be provided as a plug or cap for the insert component.
The separate component piece is substantially planar and of a substantially constant thickness.
The thickness of the separate component piece may be sufficient so as to align or be substantially matched with the second rim
The second rim may be of about a 2 mm height, the first rim may be of about a 1 mm height.
The separate component piece may be of about a 2 mm thickness.
In a second aspect there is provided a structure formed in-situ with a panel, wherein an insert as defined in the first aspect or according to any preceding statement is affixed to a face of a panel.
A rebate is formed in said face of said panel, said rebate being of a depth to receive said insert, such that an end of said second rim is substantially level or aligned with said face of said panel, or an intended level of a finished or decorated surface of said panel.
It is further contemplated that where a light fitting or fixture is described, said light fitting may be substituted with any other fitting or component to be installed into a panel, such as, speakers, furniture, ducts, piping, components of alarm or safety systems (e.g., smoke detectors, gas detectors, infrared motion detectors) or any other outlet, utility or appliance.
It is further contemplated that any such fittings or components or systems to be installed may be retrofitted with suitable adaptors for installing into a body or assembly as described in any one of the preceding aspects or embodiments.
It is further contemplated that an assembly may comprise the body as described herein, and in particular with reference to any one or more of the preceding aspects or embodiments.
The invention described herein provides for at least two separate rims, being of the same or different height projections of the first face of the body, where at least the first rim provides for a first reference height and the second rim provides for a second reference height. The reference heights being made with reference to the first face of the body or with reference to a face of a panel into which the insert is to be affixed or received.
In certain embodiments, the first rim is of a lower or smaller height or size then the second rim. In this manner, where for example a (curable) material such as a plaster is to be applied over the insert (for example to affixed of mechanically engage the insert with the panel to which it is to be affixed), a first application of a material can be made upon the insert, and an amount of material can be applied such that the material is applied to a thickness to align with the first rim. A second or subsequent layer of material may then be applied or coated, and this may be to a thickness to align with the second rim.
It will be appreciated the body of this invention may also be utilised for use in altering or reducing or amending the shape or dimension of other aspects of an aperture or opening through a panel.
In a third aspect there is provided an insert component to be affixed to a panel, said insert component comprising:
a body, the body including a first face and a second face, the body defining at least one opening extending between the first face and the second face, said at least one opening positioned within a perimeter of the body,
a flange portion extending substantially radially outwardly from one or each of said at least one opening, and
wherein at least a portion at the perimeter of the body is adjustable and/or adaptable toward and/or away from the at least one opening.
The perimeter is moveable, preferably radially, so as to provide a biasing means for retaining the body in a rebate formed in the face of a panel, the rebate being of a depth to receive said insert.
In a particular form the rebate is formed in a ceiling structure and the at least one opening is adapted to receive a lighting fixture or the like ceiling fixture such as a sensor. In a preferred form the rebate is sized so as to receive the insert with minimal clearance such that the adjustable perimeter is adjustable/adaptable to engage a side of the rebate.
A suitable retention means for adjusting the perimeter may be by way of at least one resilient element located at the perimeter of the body, adapted to provide an outward bias to retain the body of the insert in a rebate. When in a retained state a user can apply a (curable) material such as a plaster over the insert. The retention means can alternatively be termed a biasing element, perimeter expander, spring-biased member or any combination of these terms.
The resilient element may include an outward projection beyond the main perimeter. The projection may be of bevelled/tapered or spike form to engage into a surface of the rebate, in use.
The insert of the third aspect may incorporate and be combined with any or all additional features described above in relation to the first or second aspect of the invention. For example, the insert of the invention may further include projections or bumps on the rebate-facing face of the body so as to provide a spacing function of the body from the rebate inner surface and allow flow of adhesive and/or curable material such as plaster. In a fourth aspect there is provided an insert component to be affixed to a panel, said insert component comprising:
a body, the body including a first face and a second face, the body defining at least one opening extending between the first face and the second face, said at least one opening positioned within a perimeter of the body,
a flange portion located substantially radially outwardly from one or each of said at least one opening,
at least one rim provided upon said first face and substantially about a perimeter of each said opening, and
wherein said flange portion has a relatively greater wall thickness in a region adjacent to or at said rim, and is of a relatively reduced wall thickness in a region adjacent to or at said perimeter of said body.
At least one channel region may be provided in said first face and substantially about the perimeter of each said opening, said channel region located outwardly of said rim relative to said perimeter of each said opening.
The rim may be a projection extending upwardly or in a direction away from said first face and said second face.
The rim may be provided as a projection upstanding from said first face.
The channel may be provided as a recess in said first face.
The channel may be located between the rim and said flange portion.
The rim may form a first channel wall of said channel.
A height of said first channel wall may be substantially equal to or greater than a second channel wall, and the second channel wall may be located outwardly of said first channel wall relative to said perimeter of each said opening.
A height of the rim may be about 2 mm, or about 3 mm, or about 4 mm, or about 5 mm, or about 6 mm, or about 7 mm, or about 8 mm, or about 9 mm, or about 10 mm, or about 11 mm, or about 12 mm, or may be less than about 12 mm, or less than about 10 mm, or less than about 8 mm, or less than about 6 mm, or less than about 4 mm, or less than about 2 mm, as measured from said first face of said body.
The channel region may have a floor or base defining a channel region depth, said floor or base being of a level, or providing for floor or base sections of a level substantially lower than said first face of said body and/or said flange portion.
A depth of the channel may be about 1 mm, or about 2 mm, or about 3 mm, or about 4 mm, or about 5 mm, or about 6 mm, or about 7 mm, or about 8 mm, or about 9 mm, or about 10 mm, or may be less than about 10 mm, or less than about 8 mm, or less than about 6 mm, or less than about 4 mm, or less than about 2 mm, as measured from said first face of said body.
The channel may be of a pre-determined width, said width defined between said first channel wall and said second channel wall.
The width and/or said depth of said channel may be sufficient to accommodate or receive a (curable) material.
The width of the channel may be greater than about 1 mm, or greater than about 2 mm, or greater than about 3 mm, or greater than about 4 mm, or greater than about 5 mm, or greater than about 10 mm, or greater than about 15 mm, or is about 2 mm, or is about 3 mm, or is about 4 mm, or is about 5 mm, or is about 6 mm, or is about 8 mm, or is about 10 mm, or is less than 10 mm.
The material may be a filler material (such as, but not limited to, one or more of: a plaster-type or render-type material, such as a material comprising of gypsum, lime or cement material, or is a material capable of being decorated or may be a material which can be finished, e.g. can be sanded to a finished surface, for a subsequent application of a decorative material, such as paint).
One or more of said at least one opening may further comprise of a ledge, said ledge providing a support surface extending substantially inwardly toward a centre of said opening.
The support surface may be a surface facing the same direction as said first face of said body.
The support surface may be a substantially planar surface.
The support surface may comprise a channel or recess.
The support surface of said ledge may be recessed from said rim, or may be of a reduced height relative to said rim.
The support surface may provide a surface upon which an item is seatable.
The item may be one of: a light fixture or fitting, a smoke or fire alarm or detector, a sprinkler, an audio speaker, a ceiling mounted sensor, or other fittings or fixtures or devices.
The second face may comprise an inner portion and an outer portion.
The outer portion may substantially correspond with said flange portion, and the inner portion may substantially correspond with said channel and said rim.
The inner portion may be a raised or stepped region, raised or stepped in a direction to accommodate said channel.
A sidewall may define a step between said outer portion and said inner portion, and may be provided as a guide for locating said body into an aperture of a panel.
The outer portion may be substantially planar.
The outer portion comprises of an adhesive, projection or fastener, and may be adhered or affixed to a surface of a panel in use.
The outer portion may comprise one or more projections, the one or more projections being of a bevelled, tapered and/or of a spiked form.
The one or more projections may extend in a direction away from said second face, or in a direction toward a surface of a panel to which said insert is to be affixed.
The one or more projections may provide for a mechanical engagement or attachment with the panel.
The one or more projections may be provided as an array about the second face of said outer portion.
The flange portion may have a relatively greater wall thickness in the region adjacent to or at said channel, and may be of a relatively reduced wall thickness in a region adjacent to or at said perimeter of said body.
The flange portion may be of a wall thickness of about 0.5 mm in a region adjacent to or at said perimeter of said body.
The flange portion may be of a wall thickness of about 1 mm in a region adjacent to or at said channel.
The flange portion may be substantially tapered in a reducing wall thickness, said wall thickness reducing in a direction as said flange portion extends substantially radially outwardly from said channel.
The first face may comprise said rim defining a first projected height, said flange portion at or substantially adjacent to said channel defining a second projected height, and said flange portion at or substantially adjacent to said perimeter defining a third projected height.
The rim may define a first projected height of said first face, said flange portion at or substantially adjacent to said channel may define a second projected height of said first face, and said flange portion at or substantially adjacent to said perimeter may define a third projected height of said first face.
The third projected height may be less than said second projected height.
The third projected height may be less than said first projected height.
The second projected height may be less than said first projected height.
The third projected height may be less than said second projected height, and said second projected height may be less than said first projected height.
The flange portion may slope from said first projected height to said third projected height.
An outer edge of said flange portion may define said perimeter of said body.
The first face of said outer edge may comprise a chamfered edge portion.
The first face may further comprise said support surface of said ledge defining a fourth projected height.
The fourth projected height may be less than said first projected height, or matches the height of the first projected height.
The flange portion may extend substantially radially outwardly of said channel.
The flange portion may extend substantially about a part, or parts, or substantially an entirety, of said perimeter of said body.
The flange portion may extend as two opposing sides of said body (i.e. is cut-off sides), or wherein two opposing sides of said flange portion are substantially parallel.
The flange portion may comprise one or more apertures, said apertures extending through said body.
The apertures may provide for a void through said body.
The apertures may be distributed about said flange portion.
The channel may comprise one or more channel apertures, and said apertures may extend through said body.
The channel apertures may provide for a void through said body.
The channel apertures may be distributed about said channel.
The channel may comprise one or more ribs.
The one or more ribs may extend across said channel.
The one or more ribs may be strengthening members.
The one or more ribs may provide for a strengthening structure between a wall of said rim and a wall of said flange portion.
The one or more ribs may extend substantially across said channel or said floor of said channel, or between sidewalls of said channel.
The one or more ribs may be distributed about said channel.
The one or more ribs may be of a height below the first face, or said one or more ribs may be provided of a height recessed from said first face, or of said flange portion.
The body may be substantially circular, oval or of a rectilinear perimeter shape.
One or more of said at least one opening(s) may be substantially circular, oval or of a rectilinear perimeter shape.
The ledge may be substantially circular, oval or of a rectilinear perimeter shape.
A diameter of an inner perimeter of said rim may be about 25 mm to about 104 mm, or is about 76 mm, or about 86 mm, or about 102 mm, or about 103 mm, or about 104 mm, or about 105 mm, or about 106 mm, or may be about 160 mm, or may be about 200 mm, or is greater than about 10 mm, or greater than about 20 mm, or greater than about 25 mm, or greater than about 30 mm, or greater than about 35 mm, or greater than about 40 mm, or greater than about 50 mm, or greater than about 85 mm, or greater than about 100 mm, or greater than about 105 mm, or greater than about 125 mm, or greater than about 150 mm, or greater than about 175 mm, or greater than about 200 mm, or greater than about 300 mm, or greater than about 400 mm.
The flange may be detachable or attachable or integral with said body.
The rim or the channel, or both, may be detachable or attachable or integral with said body.
The ledge may be detachable or attachable or integral with said body.
A separate component piece, such as a plate-type component piece, may be provided for seating upon the ledge.
The separate component piece may be provided as a plate-type component piece comprising of one or more apertures.
The separate component piece may be provided as a plug or cap for the insert component.
The separate component piece may be substantially planar and of a substantially constant thickness.
The insert as defined in any of the first, second, third, fourth, or fifth aspects may be affixed to a face of a panel.
A rebate may be formed in said face of said panel, said rebate being of a depth to receive said insert, such that an end of said rim is substantially level or aligned with said face of said panel, or an intended level of a finished or decorated surface of said panel.
A structure may be formed in-situ with a panel, and said insert as defined in any of the first, second, third, fourth, or fifth aspects may be affixed to a face of the panel, and a rebate may be formed in said face of said panel and sized so as to receive the insert such that the at least a portion at the perimeter of the body is configured to extend to engage a side of the rebate and retain the insert therewithin the rebate.
The insert of the fourth aspect may incorporate and be combined with any or all additional features described above in relation to the first or second or third aspect, or with any or all additional features described below in relation to the fifth aspect of the invention. For example, the insert of the invention may further include projections or bumps on the rebate-facing face of the body so as to provide a spacing function of the body from the rebate inner surface and allow flow of adhesive and/or curable material such as plaster. Additionally, the insert may comprise one or more resilient elements.
In a fifth aspect there is provided an insert component to be affixed to a panel, said insert component comprising:
a body, the body including a first face and a second face, the body defining at least one opening extending between the first face and the second face, said at least one opening positioned within a perimeter of the body,
a flange portion located substantially radially outwardly from one or each of said at least one opening,
at least one rim provided upon said first face and substantially about a perimeter of each said opening, and
at least one channel region provided in said first face and substantially about the perimeter of each said opening, said channel region located outwardly of said rim relative to said perimeter of each said opening.
The rim may be a projection extending upwardly or in a direction away from said first face and said second face.
The rim may be provided as a projection upstanding from said first face.
The channel may be provided as a recess in said first face.
The channel may be located between the rim and said flange portion.
The rim may form a first channel wall of said channel.
A height of said first channel wall may be substantially equal to or greater than a second channel wall, and the second channel wall may be located outwardly of said first channel wall relative to said perimeter of each said opening.
A height of the rim may be about 2 mm, or about 3 mm, or about 4 mm, or about 5 mm, or about 6 mm, or about 7 mm, or about 8 mm, or about 9 mm, or about 10 mm, or about 11 mm, or about 12 mm, or may be less than about 12 mm, or less than about 10 mm, or less than about 8 mm, or less than about 6 mm, or less than about 4 mm, or less than about 2 mm, as measured from said first face of said body.
The channel region may have a floor or base defining a channel region depth, said floor or base being of a level, or providing for floor or base sections of a level substantially lower than said first face of said body and/or said flange portion.
A depth of the channel may be about 1 mm, or about 2 mm, or about 3 mm, or about 4 mm, or about 5 mm, or about 6 mm, or about 7 mm, or about 8 mm, or about 9 mm, or about 10 mm, or may be less than about 10 mm, or less than about 8 mm, or less than about 6 mm, or less than about 4 mm, or less than about 2mm, as measured from said first face of said body.
The channel may be of a pre-determined width, said width defined between said first channel wall and said second channel wall.
The width and/or said depth of said channel may be sufficient to accommodate or receive a (curable) material.
The width of the channel may be greater than about 1 mm, or greater than about 2 mm, or greater than about 3 mm, or greater than about 4 mm, or greater than about 5 mm, or greater than about 10 mm, or greater than about 15 mm, or is about 2 mm, or is about 3 mm, or is about 4 mm, or is about 5 mm, or is about 6 mm, or is about 8 mm, or is about 10 mm, or is less than 10 mm.
The material may be a filler material (such as, but not limited to, one or more of: a plaster-type or render-type material, such as a material comprising of gypsum, lime or cement material, or is a material capable of being decorated or may be a material which can be finished, e.g. can be sanded to a finished surface, for a subsequent application of a decorative material, such as paint).
One or more of said at least one opening may further comprise of a ledge, said ledge providing a support surface extending substantially inwardly toward a centre of said opening.
The support surface may be a surface facing the same direction as said first face of said body.
The support surface may be a substantially planar surface.
The support surface may comprise a channel or recess.
The support surface of said ledge may be recessed from said rim, or may be of a reduced height relative to said rim.
The support surface may provide a surface upon which an item is seatable.
The item may be one of: a light fixture or fitting, a smoke or fire alarm or detector, a sprinkler, an audio speaker, a ceiling mounted sensor, or other fittings or fixtures or devices.
The second face may comprise an inner portion and an outer portion.
The outer portion may substantially correspond with said flange portion, and the inner portion may substantially correspond with said channel and said rim.
The inner portion may be a raised or stepped region, raised or stepped in a direction to accommodate said channel.
A sidewall may define a step between said outer portion and said inner portion, and may be provided as a guide for locating said body into an aperture of a panel.
The outer portion may be substantially planar.
The outer portion comprises of an adhesive, projection or fastener, and may be adhered or affixed to a surface of a panel in use.
The outer portion may comprise one or more projections, the one or more projections being of a bevelled, tapered and/or of a spiked form.
The one or more projections may extend in a direction away from said second face, or in a direction toward a surface of a panel to which said insert is to be affixed.
The one or more projections may provide for a mechanical engagement or attachment with the panel.
The one or more projections may be provided as an array about the second face of said outer portion.
The flange portion may have a relatively greater wall thickness in the region adjacent to or at said channel, and may be of a relatively reduced wall thickness in a region adjacent to or at said perimeter of said body.
The flange portion may be of a wall thickness of about 0.5 mm in a region adjacent to or at said perimeter of said body.
The flange portion may be of a wall thickness of about 1 mm in a region adjacent to or at said channel.
The flange portion may be substantially tapered in a reducing wall thickness, said wall thickness reducing in a direction as said flange portion extends substantially radially outwardly from said channel.
The first face may comprise said rim defining a first projected height, said flange portion at or substantially adjacent to said channel defining a second projected height, and said flange portion at or substantially adjacent to said perimeter defining a third projected height.
The rim may define a first projected height of said first face, said flange portion at or substantially adjacent to said channel may define a second projected height of said first face, and said flange portion at or substantially adjacent to said perimeter may define a third projected height of said first face.
The third projected height may be less than said second projected height.
The third projected height may be less than said first projected height.
The second projected height may be less than said first projected height.
The third projected height may be less than said second projected height, and said second projected height may be less than said first projected height.
The flange portion may slope from said first projected height to said third projected height.
An outer edge of said flange portion may define said perimeter of said body.
The first face of said outer edge may comprise a chamfered edge portion.
The first face may further comprise said support surface of said ledge defining a fourth projected height.
The fourth projected height may be less than said first projected height, or matches the height of the first projected height.
The flange portion may extend substantially radially outwardly of said channel.
The flange portion may extend substantially about a part, or parts, or substantially an entirety, of said perimeter of said body.
The flange portion may extend as two opposing sides of said body (i.e. is cut-off sides), or wherein two opposing sides of said flange portion are substantially parallel.
The flange portion may comprise one or more apertures, said apertures extending through said body.
The apertures may provide for a void through said body.
The apertures may be distributed about said flange portion.
The channel may comprise one or more channel apertures, and said apertures may extend through said body.
The channel apertures may provide for a void through said body.
The channel apertures may be distributed about said channel.
The channel may comprise one or more ribs.
The one or more ribs may extend across said channel.
The one or more ribs may be strengthening members.
The one or more ribs may provide for a strengthening structure between a wall of said rim and a wall of said flange portion.
The one or more ribs may extend substantially across said channel or said floor of said channel, or between sidewalls of said channel.
The one or more ribs may be distributed about said channel.
The one or more ribs may be of a height below the first face, or said one or more ribs may be provided of a height recessed from said first face, or of said flange portion.
The body may be substantially circular, oval or of a rectilinear perimeter shape.
One or more of said at least one opening(s) may be substantially circular, oval or of a rectilinear perimeter shape.
The ledge may be substantially circular, oval or of a rectilinear perimeter shape.
A diameter of an inner perimeter of said rim may be about 25 mm to about 104 mm, or is about 76 mm, or about 86 mm, or about 102 mm, or about 103 mm, or about 104 mm, or about 105 mm, or about 106 mm, or may be about 160 mm, or may be about 200 mm, or is greater than about 10 mm, or greater than about 20 mm, or greater than about 25 mm, or greater than about 30 mm, or greater than about 35 mm, or greater than about 40 mm, or greater than about 50 mm, or greater than about 85 mm, or greater than about 100 mm, or greater than about 105 mm, or greater than about 125 mm, or greater than about 150 mm, or greater than about 175 mm, or greater than about 200 mm, or greater than about 300 mm, or greater than about 400 mm.
The flange may be detachable or attachable or integral with said body.
The rim or the channel, or both, may be detachable or attachable or integral with said body.
The ledge may be detachable or attachable or integral with said body.
A separate component piece, such as a plate-type component piece, may be provided for seating upon the ledge.
The separate component piece may be provided as a plate-type component piece comprising of one or more apertures.
The separate component piece may be provided as a plug or cap for the insert component.
The separate component piece may be substantially planar and of a substantially constant thickness.
The insert as defined in any of the first, second, third, fourth, or fifth aspects may be affixed to a face of a panel.
A rebate may be formed in said face of said panel, said rebate being of a depth to receive said insert, such that an end of said rim is substantially level or aligned with said face of said panel, or an intended level of a finished or decorated surface of said panel.
A structure may be formed in-situ with a panel, and said insert as defined in any of the first, second, third, fourth, or fifth aspects may be affixed to a face of the panel, and a rebate may be formed in said face of said panel and sized so as to receive the insert such that the at least a portion at the perimeter of the body is configured to extend to engage a side of the rebate and retain the insert therewithin the rebate.
The insert of the fifth aspect may incorporate and be combined with any or all additional features described above in relation to the first or second or third or fourth aspect of the invention. For example, the insert of the invention may further include projections or bumps on the rebate-facing face of the body so as to provide a spacing function of the body from the rebate inner surface and allow flow of adhesive and/or curable material such as plaster. Additionally, the insert may comprise one or more resilient elements.
The term “comprising” as used in this specification means “consisting at least in part of”. When interpreting each statement in this specification that includes the term “comprising”, features other than that or those prefaced by the term may also be present. Related terms such as “comprise” and “comprises” are to be interpreted in the same manner.
This invention may also be said broadly to consist in the parts, elements and features referred to or indicated in the specification of the application, individually or collectively, and any or all combinations of any two or more said parts, elements or features, and where specific integers are mentioned herein which have known equivalents in the art to which this invention relates, such known equivalents are deemed to be incorporated herein as if individually set forth.
The invention consists in the foregoing and also envisages constructions of which the following gives examples only.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred embodiments of the invention will be described by way of example only and with reference to the drawings, in which:

FIG. 1 illustrates a top perspective view of one embodiment of an insert component,

FIG. 2 illustrates a bottom perspective view of one embodiment of an insert component,

FIG. 3 illustrates a side or elevation view of one embodiment of an insert component,

FIG. 4 illustrates a top or plan view of one embodiment of an insert component,

FIG. 5 illustrates a bottom view of one embodiment of an insert component,

FIG. 6 illustrates a cross-sectional view (section AA as shown in FIG. 5) through an embodiment of an insert component,

FIG. 7 illustrates a section of an insert component according to the present invention illustrating how the insert component can be located into a rebate of a panel, and different layers of materials applied to affix the insert component into place,

FIG. 8 illustrates a separate component piece which may be provided for seating upon a ledge of an insert component, to provide for a plug-type arrangement,

FIG. 9 illustrates how a separate component piece of, for example that of

FIG. 8, may be received by an insert component,

FIG. 10 illustrates a top perspective view of a second embodiment of an insert component,

FIG. 11 illustrates a bottom perspective view of the second embodiment of insert component,

FIG. 12 illustrates a side or elevation view of the second embodiment of insert component, and

FIG. 13 illustrates a section of an insert component according to the second embodiment illustrating how the insert component can be located into a rebate of a panel, and different layers of materials applied to affix the insert component into place,

FIG. 14 illustrates a bottom perspective view of a third embodiment of an insert component,

FIG. 15 illustrates a top perspective view of the third embodiment of an insert component,

FIG. 16 illustrates a side or elevation view of the third embodiment of an insert component,

FIG. 17 illustrates a bottom view of the third embodiment of an insert component,

FIG. 18 illustrates a top view of the third embodiment of an insert component,

FIG. 19 illustrates a cross-sectional view (section BB as shown in FIG. 17) through an insert component according to the third embodiment,

FIG. 20 illustrates a section of an insert component according to the third embodiment illustrating how the insert component can be located into a rebate of a panel, and different layers of materials applied to affix the insert component into place,

FIG. 21 illustrates a section of an insert component according to a third embodiment illustrating differences in height of an insert component first face due to a rim and a taper of a flange section,

FIG. 22 illustrates a bottom view of the third embodiment of an insert component including projections on a flange portion, and

FIG. 23 illustrates a side or elevation view of the third embodiment of an insert component including projections on a flange portion.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

This invention provides for an insert component 1, that can provide for a member in the form of a body 2, to which a fitting or fixture may be mounted or seated upon and supported. Such a member can provide for a particular structural support for a fitting or fixture to be supported thereon or thereto.
The insert component 1 can also provide for a particular or pre-determined (i.e. a pre-formed) dimensioned or shaped opening. Such an opening providing for receipt of a fitting or fixture. Such a particularly dimensioned or shaped opening provided by the insert component may facilitate the re-sizing or alteration in shape of an existing aperture in a panel, the insert component capable of receiving such a fitting of fixture.
The insert component (as described herein) can be located or positioned into a rebate or recessed region of a panel, such that the insert component can be subsequently mechanically fixed into place, for example by application of one or more layers of material, such as a curable material like plaster or other curable medium or adhesives. In this manner, the insert component can be integrated into the panel. The insert component then provides a particular structure for assisting with such an integration and as a support for a fixture of fitting.
This invention also provides for a relatively uncomplicated system for reducing the geometry, such as shape or size of an existing aperture, whilst as the same time provides a platform upon which materials, such as concealing compositions—e.g. plaster, paint or other fillers or finishes, may be applied to conceal the joint region between the insert component and the surrounding panel.
It will also be appreciated the present invention may be utilised for improving or strengthening the aperture or opening cut or made in a building panel to receive a fitting, such as a light fitting (or any other outlet or utility requiring an aperture through a building panel) or a wall socket (such as for electrical outlets or indeed any other outlet requiring an aperture through a building panel). For example, the existing aperture or opening referred to here may be the aperture which is initially cut or made in a building panel to then receive a fitting or fixture.
The insert component of the invention facilitates an improvement in the strength of the building panel around an aperture or opening through the panel and any finishes made about the aperture so cut or made, and in this way can help to minimise possible “break-out” in which the materials used around the aperture or opening are compromised as to their structural integrity due to forces imposed upon them, for example by a light fitting imparting a force on a building panel about the aperture. “Break out” may result in cracking of plaster or paint or other unsightly effects in decorative finishes around the aperture.
The insert component can facilitate the alteration in the shape or size of an aperture or opening through a panel, for example a building panel such as a ceiling or a wall. The following description is provided as exemplary of the invention, and is made with reference to the accompanying drawings.
Accordingly, described below are particular details of one embodiment of an insert component.
In one embodiment there is provided an insert component 1 to be affixed to, for example, a panel (P, see FIG. 7). The insert component 1 comprises a body 2. The body 2 includes a first face 3 and a second face 4. The body 1 defines at least one opening 5 that extends between the first face 3 and the second face 4. The at least one opening 5 is positioned within a perimeter (such as an outer perimeter) of the body 1. A flange portion 6 extending substantially radially outwardly from one or each of said at least one opening 5. At least one first rim 7 is provided upon the first face 3 and substantially about a perimeter of each opening 5. At least one second rim 8 is provided upon the first face 3 and substantially about the perimeter of each opening 5. The first rim 7 is located outwardly of the second rim 8, relative to the perimeter of each opening 5. Each of the first rim 7 and the second rim 8 are spaced from each other to define a channel region 9 therebetween.
While a single opening 5 is shown in the accompanying figures, it will be appreciated that the body 2 may be of any shape or size and could accommodate any number of openings, where one or more of those openings can each be provided with the first rim and the second rim with the channel region located between those rims. In this manner, the number of openings 5 in a body 2 may be customised according to the number of fittings or fixtures which are to be received by the insert component 1.
As is for example shown in the figures, each of the first rim 7 and second rim 8 may be of the form of projections which extend in a direction upwardly or away from said first face 3 of the body 1. That is, the first and second rims are provided as projections upstanding from the first face 3.
The first rim 7 can be of a first rim height 7H relative to the first face 3 surface of said flange portion 6, while the second rim 8 can be of a second rim height 8H relative to a first face 3 surface of the flange portion 6.
The first rim height 7H can be substantially equal to or less than the second rim height 8H. Expressed in an alternative manner, the second rim height 8H can be substantially equal to or greater than the first rim height 7H.
Depending on the situational use, the first rim height 7H may be of a height that is less than the second rim height 8H.
In one example, the height 7H of the first rim 7 may be about 1 mm, as measured from the first face 3 of the body 1 to the most distal tip or end of the first rim 7. In various other embodiments, a height of the first rim may be about 1 mm, or about 2 mm, or about 3 mm, or about 4 mm, or about 5 mm, or about 6 mm, or about 7 mm, or about 8 mm, or about 9 mm, or about 10 mm, or may be less than about 10 mm, or less than about 8 mm, or less than about 6 mm, or less than about 4 mm, or less than about 2 mm, as measured from said first face of said body.
In another example, the height 8H of the second rim 8 may be about 2 mm, as measured from the first face 3 of the body 1 to the most distal tip or end of the second rim 7. In various other embodiments, a height of the second rim may be about 2 mm, or about 3 mm, or about 4 mm, or about 5 mm, or about 6 mm, or about 7 mm, or about 8 mm, or about 9 mm, or about 10 mm, or about 11 mm, or about 12 mm, or may be less than about 12 mm, or less than about 10 mm, or less than about 8 mm, or less than about 6 mm, or less than about 4 mm, or less than about 2 mm, as measured from said first face of said body.
The channel region 9 has a floor or base which defines a channel region depth 9H. The floor or base of the channel region 9 is of a level, or provides for a floor or base sections of a level, which may be one or more of:
a level that is substantially equal to the level of the first surface 3 or of the flange portion 6,
a level that is substantially lower than the level of the first surface 3 or of said flange portion 6,
a level substantially higher than the level of the first surface 3 or of the flange portion 6.
The channel may be configured to be provided with a continuous floor or base, or the floor or base may be of a discontinuous form (i.e. the floor or base may comprise of apertures).
The depth of the channel region is advantageously sufficient so as to allow for a depth or thickness of material to be applied and to in-fill the channel region 9.
The channel may be of a width that is greater than about 1 mm, or greater than about 2 mm, or greater than about 3 mm, or greater than about 4 mm, or greater than about 5 mm, or greater than about 10 mm, or greater than about 15 mm, or may be about 2 mm, or may be about 3 mm, or may be about 4 mm, or may be about 5 mm, or may be about 6 mm, or may be about 8 mm, or may be about 10 mm, or may be less than 10 mm.
The depth and/or width of the channel region 9 can provide for a region of increased material, and accordingly can provide for a stronger bond or stronger plaster edge or edge of material which is joining the insert component 1 to the surrounding panel material.
The channel region 9 is of a pre-determined width. This width can be defined between the facing side walls of each of the first rim 7 and the second rim 8.
The width of the channel region is sufficient so as to accommodate or receive a (curable) material.
The material may be a filler material, such as, but not limited to, one or more of: a plaster-type or render-type material, such as a material comprising of gypsum, lime or cement material, or is a material capable of being decorated or may be a material which can be finished, e.g. can be sanded to a finished surface, for a subsequent application of a decorative material, such as paint.
The insert component 1 can optionally also comprises of a ledge 10.
A ledge 10 can be provided for one or more, or each of, the at least one opening(s) 5 of in the body 2.
The ledge 10 can provide a support surface 11 that extends substantially inwardly toward a centre of the opening 5 to which the ledge 10 is provided. That is, one or more, or all, of the openings through the body 2 can be provided with a ledge 10, each such ledge providing its own support surface 11.
The support surface 11 allows for the seating or receipt thereon of a fixture or fitting or another item or device which is to be received within the opening 5. The ledge 10 with its support surface 11 provides a structure upon which the fixture or fitting or item or device can be received or seated thereon.
The support surface 11 can be a surface of the ledge which faces in substantially the same direction as the first face 3 of the body 2. It will be appreciated that the support surface of the ledge may be another surface of the ledge 10, and is not limited necessarily to being the surface identified as item 11. For example, a rear side surface labelled as item 12 may be used as the support surface, but in that case such a surface 12 would face in a different direction.
The support surface (whether as a surface 11 or 12) can be a substantially planar or flat surface, although it will be appreciated that other formations (not shown) may be provided upon the surface (11 or 12) to facilitate a suitable seating of a fixture or fitting or item or device.
The support surface advantageously provides a surface or a platform upon which an item is received thereon or is seatable.
The fixture or fitting may be a light fixture or a light fitting, or may be a smoke alarm or smoke detector or other fittings or fixtures or devices.
The second face 4 of the body 2 can comprises one or more projections 13.
The projections 13 provided on the second face 4 of the body 2 can extend a pre-determined height or distance away from the second face 4.
The projections 13, in-use, allowing for a spacing of the second face 4 and therefore the body 2, away from a surface (e.g. a surface of a panel) upon which the second face is to be located. That is, the projections 13 provide or facilitate a gap or a space to be formed between the second face 4 and the surface upon which the body is to be located (e.g. panel surface onto which the insert component is to be positioned or located).
It is the space or gap formed by the projections 13 which mean a void is created between the body 2 and the surface to which the insert component is to be affixed into which a (optionally curable) material can be in-filled.
The one or more projections 13 can be distributed about the second face 4. The distribution may be in a manner so as to substantially evenly support or space the second face of the body 2 from the surface upon which the insert component is to be affixed. In various embodiments, the projections 13 may be distributed substantially evenly or equidistantly from each other and about the second face 4.
In one particular embodiment there may be six projections provided upon the second face of the body 2, although it will be appreciated that any number of projections may be provided.
The projections upon the second face may be of a pre-determined height or extend a distance away from the second face of about 0.5 mm, or about 1 mm, or may be less than about 5 mm, or less than about 4 mm, or less than about 3 mm, or less than about 2 mm, or less than about 1 mm, or less than about 0.5 mm.
The flange portion 6 can extend substantially about a part, or parts, or substantially an entirety, of the perimeter, such as the outer perimeter, of the body 2.
The flange portion may be of any size, shape or dimension suitable for providing a region which extends the surface area for affixation of the insert component 1 to a surface.
Particularly where a curable medium or material (e.g. plaster) is used for affixation of the insert component 1 to a surface, an increase in surface area of the insert component may be advantageous for increasing or improving the surface area for a mechanical adhesion.
The flange portion 6 can be provided as two opposing sides of said body (i.e. there are cut-off or straight side portions).
The flange portion 6 can have one or more apertures 14, the apertures 14 extending through the body 2. The apertures 14 can provide for voids through the body 2.
The apertures 14 can be distributed about the flange portion.
The apertures 14 can be a series of similar sizes and shapes, or may be the same or may be differently sized and shaped.
The apertures 14 allow for a curable material or medium, when applied to the first face 3, to be pushed through the apertures 14 so as to fill and be provided in contact with a surface of a panel to which the insert component is being affixed.
Where for example the projections 13 are provided, then the apertures 14 also allow for the material or medium to be applied and be applied through to fill in the space or gap or void created by the projections 13 standing the second face 4 off of the surface of a panel. This allows for greater amounts of material or medium to be applied and to be provided for improved mechanical adhesion or connection between the surface and the insert component.
Optionally, a sufficient amount or quantity of material or medium can be applied so as to encapsulate the insert component 1 and to retain the insert component in-situ.
The second face 4 of the body 2 may be provided as a substantially planar surface, apart from the optional one or more projections 13 which would otherwise be provided thereon.
However, other formations (not shown) may be provided on the second face 4 to facilitate further stand-off of the body from a surface to which the insert component is to be affixed, or may comprise of yet other functional formations which facilitate improve or greater mechanical connection of the insert component 1 to a surface of a panel.
It will be appreciated that the insert component 1 may be of any shape or dimension, but particularly preferably may be shapes which are substantially circular, oval or of a rectilinear perimeter shape.
It will be appreciated that the opening 5 may be of any shape or dimension, but particularly preferably may be shapes which may be substantially circular, oval or of a rectilinear perimeter shape.
It will be appreciated that the ledge 10 may be of any shape or dimension, but particularly preferably may be shapes which are substantially circular, oval or of a rectilinear perimeter shape, or are suitable shaped and dimensioned relative to the shape and dimension of an associated opening 5.
A diameter of an inner perimeter of said second rim may be about 25 mm to about 104 mm, or may be about 76 mm, or may be about 86 mm, or about 102 mm, or about 103 mm, or about 104 mm, or about 105 mm, or about 106 mm, or may be about 160 mm, or may be about 200 mm, or may be greater than about 10 mm, or greater than about 20 mm, or greater than about 25 mm, or greater than about 30 mm, or greater than about 35 mm, or greater than about 40mm, or greater than about 50 mm, or greater than about 85 mm, or greater than about 100 mm, or greater than about 105 mm, or greater than about 125 mm, or greater than about 150 mm, or greater than about 175 mm, or greater than about 200 mm, or greater than about 300 mm, or greater than about 400 mm. The diameter may be of any diameter, but the above diameters may have particular application utility.
The flange portion 6 can be provided as a component which is detachable or attachable or that is integral with the body 2.
The first rim 7 or the second rim 8, or both first and second rims, can be provided as a component or as each separate components, which are separately or in a combined manner, detachable or attachable or with the body 2.
The ledge 10 can be provided as a component that is detachable or attachable or that is integral with the body 2.
The projections 13 can be provided as separate components, or a combined component, for provision upon the second face 4 of the body 2, that is detachable or attachable or that is integral with the body 2.
As for example shown in FIG. 8, a separate component piece 15 can be provided. Such a component piece 15 may for example be in the form of a plate-type component piece. Such a separate component piece 15 may be provided for seating upon the ledge 10.
The separate component 15 piece may comprise one or more apertures 16, which are configured to allow for the ingress of a material or medium as described elsewhere herein.
The separate component piece 15 can be provided as a plug or cap for the insert component 1. In this way, the insert component 1 can be put into position with respect to a panel P, and then the component piece 15 can be separately installed upon the insert component 1. It will be appreciated that the component piece 15 may be provided with additional formations to facilitate an improved quality of connection with the insert component or with a material or medium which is to be applied thereon.
In one embodiment, the separate component piece 15 is substantially planar and of a substantially constant thickness. The thickness of the separate component piece may be sufficient so as to align or be substantially matched with the second rim.
In a particular example, the second rim may be of about a 2 mm height, the first rim may be of about a 1 mm height. Optionally, where a component piece 15 is also used, then the separate component piece may be of about a 2 mm thickness.
FIG. 9 illustrates the assembly or relative positioning of the component piece 15 upon the ledge of the insert component 1.
As for example shown in FIG. 7, an insert component 1 can be positioned into a rebated region R of a panel P. The insert component 1 can then be mechanically affixed in place, for example by application of one or more layers of material or medium M.
According to the above description, there is provided herein for an insert component 1. The insert component 1 has desirable utility in providing for a structure to assist with the support of a fixture or fitting or other item or device which is to be provided in a panel (such as a ceiling or wall).
In one preferred mode of installation, the insert component 1 is to be positioned within a rebated region of a panel surface. The rebate being of sufficient depth to accommodate the insert component 1. The rebate can be of a depth such that the tip or distal end of the second rim 8 is substantially in-line with the surface of the panel into which the insert component 1 is to be received. That is, a rebate can be formed in a face of a panel, with the rebate being of a depth to receive said insert, such that an end or tip or distal point of the second rim is substantially level or aligned with the face of the panel, or an intended level of a finished or decorated surface of the panel.
It is further contemplated that where a light fitting or fixture is described, said light fitting may be substituted with any other fitting or component to be installed into a panel, such as, speakers, furniture, ducts, piping, components of alarm or safety systems (e.g., smoke detectors, gas detectors, infrared motion detectors) or any other outlet, utility or appliance.
It is further contemplated that any such fittings or components or systems to be installed may be retrofitted with suitable adaptors for installing into a body or assembly as described in any one of the preceding aspects or embodiments.
It is further contemplated that an assembly may comprise the body as described herein, and in particular with reference to any one or more of the preceding aspects or embodiments.
The invention described herein provides for at least two separate rims, being of the same or different height projections of the first face of the body, where at least the first rim provides for a first reference height and the second rim provides for a second reference height. The reference heights being made with reference to the first face of the body or with reference to a face of a panel into which the insert is to be affixed or received.
In certain embodiments, the first rim is of a lower or smaller height or size then the second rim. In this manner, where for example a (curable) material such as a plaster is to be applied over the insert (for example to affixed of mechanically engage the insert with the panel to which it is to be affixed), a first application of a material can be made upon the insert, and an amount of material can be applied such that the material is applied to a thickness to align with the first rim. A second or subsequent layer of material may then be applied or coated, and this may be to a thickness to align with the second rim.
The insert component 1 can be formed in any manner. However preferred may be casting or moulding, such as injection moulding or extrusion moulding, depending on the shape of the body 2 and the other features which may be provided.
Various individual or combinations or compound materials may be used to form the insert component 1. The material to use will depend on the specific application or use.
Examples of materials comprise one or more of: polymers such as PE, PP, PET, metals such as stainless steel, aluminium, and fibrous plasters such as compositions comprising gypsum, polymers, metals, compositions comprising fibrous reinforcement, including cementitious fibre reinforced materials, fibre-glass materials.
It will also be appreciated sections or parts or portions of the insert component 1 may be formed of a combination or materials.
Yet further, it may be desirable for the insert component 1 to achieve certain desired characteristics in terms of structural strength, fire or chemical resistance or ability to retard fire. For example, components or compounds may be included in the body or the body so formed to achieve: electrical conductivity, anti-static properties, electrically insulation, fire resistance or fire retarding capabilities, or even fire self-extinguishing properties.
Where reference in this specification is made to a “panel”, such a panel may include building panels, such as ceiling panels or wall panels. In certain typical applications, panel may be a building panel of fibrous plaster comprising gypsum.
As described above, material or medium or adhesive or other bonding or curable agents may be utilised to assist or provide for affixation or connection or engagement or inter-connection the insert component 1 and surfaces of the panel. In these situations, an adhesive may be pre-applied or provided upon the insert component 1 (such as upon the second face 4). The adhesive or bonding agent may have a removal backing, such as a paper or sheet, which once removed exposes the adhesive or bonding agent for use.
In various embodiments, the adhesive or bonding agent may be curable by exposure to the surface which it is desired to come into contact with. Alternatively, another means may be used to facilitate curing—such as heat source, for example infra-red, or another energy source, for example ultra-sound, to excite the adhesive and set-off the curing process.
The materials or mediums or other agents can be passively or actively activated to cure and adhere to the panel so as to secure the insert component 1 in position.
A concealing step allows for application of a sufficient amount of the one or more materials as discussed above. Application of the material is performed by a user until the first or front face is made level with the face of the panel. Decoration or finishing materials can then be finally applied.
Sufficient amounts of material, such as plaster or similar materials, can be applied upon the insert component 1 and the building panel, then allowing the material, such as plaster to cure, and then polishing the material, such as sanding of plaster or similar material, to achieve a finished surface, optionally with a further final finishing material, such as a paint, applied.
Various tapes, such as a jointing tape, may be optionally applied about joint regions between the front face and the first face of the panel, although the present invention may allow a user to wholly negate the use of such an additional joint concealing material.
FIGS. 10 to 13 illustrate an additional feature aspect for the insert, being a perimeter retention means to hold the insert in place in a rebate, however, the features as described above, alone or in combination, are interchangeable and compatible with the retention feature.
Referring to FIG. 10 there is provided an insert component 21 to be affixed to, for example, a panel (P, see FIG. 13). The insert component 21 comprises a body 22. The body 22 includes a first face 23 and a second face 24. The body 21 defines at least one opening 25 that extends between the first face 23 and the second face 24. The at least one opening 25 is positioned within a perimeter 26 (such as an outer perimeter) of the body 21.
In the illustrated form the perimeter is comprised of radially extending fingers to provide a broken circumference, however, this is merely a one possible form (e.g. implemented for material saving measures and greater surface area in contact with a curing material/adhesive) that may be, instead, an unbroken circular perimeter as shown in FIG. 1.
As above, the opening 25 may include a rim structure, e.g. first rim 27 provided upon the first face 23 and substantially about a perimeter of each opening 25. A second rim 28 may be provided upon the first face 23 and substantially about the perimeter of each opening 25, where the first rim 27 is located outwardly of the second rim 28, relative to the perimeter of each opening 25. Each of the first rim 27 and the second rim 28 are spaced from each other to define a channel region 29 therebetween. However, it is noteworthy that this feature is an independent aspect from the general concept of a perimeter retention means as will be hereinafter described.
To assist a user in holding the body 22 in place when inserted into a rebate, at least one perimeter retention means 30 is provided. In the illustrated form there are three such retention devices 30 spaced, preferably evenly, about the perimeter 26. In the illustrated form the retention device/means is comprised of a resilient member 31 spanning between radially extending fingers such that, when a mid-point is depressed, it will flex inwardly (toward opening 25) and bounce back outwardly (away from opening 25).
Resilient member 31 preferably includes a protrusion 32 at the mid-point such that outward bias is directed through the protrusion 32 and onto any surface with which it is contacted. In the preferred usage situation, the surface in contact with perimeter protrusion 32 will be the edge/side wall of a rebate into which the body is inserted. This is generally illustrated by FIG. 13 where a tapered/sharp edge 33 of protrusion 32 may bite into rebate wall R. Once held in place by the outward bias of one or more retention devices 30 a user can apply material M across the exposed first face 23 which will incorporate the body permanently into the panel/ceiling structure.
Alternative forms of biasing/resilient/retention device are possible without departing from the scope of the invention. For example, an outwardly biased member (31, 32) may be mounted from a spring-loaded structure to generally provide the function of expanding the perimeter into engagement with a rebate wall or a sliding (biased or otherwise moveable radially outwardly) member (e.g. a spike) may extend into engagement with the rebate wall R.
Any of the disclosed insert components, such as insert component 41 shown in FIGS. 14 to 23, can provide for a member in the form of a body 42, to which a fitting or fixture may be mounted to, or seated upon, and thereby supported. Such a member can be provided as a structural support for a fitting or fixture to be supported thereon or thereto.
The insert component 41 can also provide for a particular or pre-determined (i.e. a pre-formed) dimensioned or shaped opening 45. Such an opening 45 providing the aperture for receipt therein of a fitting or fixture. Such a particularly dimensioned or shaped opening 45 provided by the insert component may facilitate the re-sizing or alteration in shape of an existing aperture in a panel, the insert component capable of receiving such a fitting of fixture. For example, the removal of traditional incandescent or halogen type light fittings and replacement by smaller format light fittings (e.g. LED lights) creates an issue of an overly large sized hole in a panel, with a smaller format light fitting to be replaced into that large(r) hole. As a consequence, a device which is capable of being provided in-situ into an existing aperture, yet which provides for a smaller (new) aperture to receive the new (smaller format) light fitting is advantageous. Similarly, in cases where retro-fitting of light is not needed, but instead in new builds or for new apertures being cut into panels, a device which provides for a suitable functionality to improve structural performance and reduce risks of break out in a friable panel (e.g. a plaster-type panel which may become compromised as to structural integrity about an aperture cut therein).
The insert component (as described herein) can be located or positioned into a rebate or recessed region of a panel, such that the insert component can be subsequently mechanically fixed into place, for example by application of one or more layers of material, such as a curable material like plaster or other curable medium or adhesives, or an adhesive tape, double sided tape, or by the use of fixing means or fasteners. In this manner, the insert component can be integrated or become more integrated into the panel. The insert component can then provide a particular structure for assisting with such an integration and as a support for a fixture of fitting.
For example, a contact or pressure sensitive adhesive may be provided on a second face of the insert (being the face which is to be put into contact with the panel), and may be revealed upon removal of a release or peel sheet. Alternatively, an adhesive may be provided which is heat cured or otherwise cures upon contact or placement when placed against the panel to which the insert is to be mounted or affixed.
This invention can also provide for a relatively uncomplicated system for reducing or altering the geometry, such as shape or size of an existing aperture, whilst at the same time provides a platform upon which materials, such as concealing compositions—e.g. plaster, paint or other fillers or finishes, may be applied to conceal the joint region between the insert component and the surrounding panel.
It will also be appreciated the present invention may be utilised for improving or strengthening the aperture or opening cut or made in a building panel to receive a fitting, such as a light fitting (or any other outlet or utility requiring an aperture through a building panel) or a wall socket (such as for electrical outlets or indeed any other outlet requiring an aperture through a building panel). For example, the existing aperture or opening referred to here may be the aperture which is initially cut or made in a building panel to then receive a fitting or fixture.
The insert component 41 of the invention may facilitate an improvement in the strength of the building panel around an aperture or opening through the panel and any finishes made about the aperture so cut or made, and in this way can help to minimise possible “break-out” in which the materials used around the aperture or opening are compromised as to their structural integrity due to forces imposed upon them, for example by a light fitting imparting a force on a building panel about the aperture. “Break out” may result in cracking of plaster or paint or other unsightly effects in decorative finishes around the aperture.
The insert component can facilitate the alteration in the shape or size of an aperture or opening through a panel, for example a building panel such as a ceiling or a wall.
The insert component 41 as described herein can advantageously provide for ease of installation to or on a panel. In an example, the insert 41 can be temporarily held in place with an adhesive, fastener, or tape, such as a double-sided tape, a pin, screw, or nail, or a projection (such as a spiked projection) formed on a flange 47 or second face 44 of the insert, to mechanically engage with a panel. In such an example, a curable adhesive m, such as a plaster, can be applied to the insert 41 to more permanently affix the insert, whilst the temporary attachment means can hold the insert in place during said curing.
In some examples, a second face 44 of the insert may comprise two portions 51 and 52, with one portion 51 being a stepped or raised region. In an example, the stepped region may comprise a sidewall 51A arranged to align the insert 41 to an aperture in a panel, and or retain the insert 41 in an aperture in a panel.
The insert 41 as described herein may provide for a panel surface mounted component which can be aligned with an aperture in a panel, whether the aperture is a pre-existing aperture (i.e. for resizing of an existing hole in a panel or other retro-fitting capabilities) or a new/fresh hole (i.e. for new builds, or new installations of fixtures into panels). The insert may also be used to fill an existing hole (i.e. for removing a fixture from a wall, and filling the existing hole).
The insert 41 as described herein may provide for a relatively low profile, and may include a tapered region from an outer perimeter 46 towards an inner portion, the insert being thinner in profile towards an outer perimeter 46. In such an example, a plaster applied to said insert can taper to provide a more gradual change in surface on a panel. This may result in a reduced bulge appearance of the insert when installed in a panel.
The insert as described herein may be provided with a rim, such as rim 48 in FIG. 15, configured to act as a wall or edge to contain or align an adhesive material applied to the insert. Additionally, the channel 49 may also provide for a means to accept adhesive applied to the insert. Alone or in combination, the rim 48 and/or channel 49 may provide for a means of containing a curable adhesive applied to the insert, and as a guide when finishing the curable adhesive (for example, when sanding after curing) to provide a clean or neat appearance to an edge of the curable adhesive surrounding the aperture of the insert 41.
FIGS. 14 to 23 illustrate an example embodiment of an insert. FIGS. 14 and 15 shown perspective views of a second face 44 and a first face 43 of the insert 41.
The insert 41 of FIGS. 14 to 23 can be affixed to a panel, and comprises a body 42, the body comprising a first face 43 and a second face 44. The body 42 defines at least one opening 45 extending between the first face 43 and the second face 44, said at least one opening 45 positioned within a perimeter 46 of the body 42. A flange portion 47 is located substantially radially outwardly from one or each of said at least one opening 45.
At least one rim 48 is provided upon said first face and substantially about a perimeter of each said opening 45. At least one channel region 49 is provided in said first face 43, and substantially about the perimeter of each said opening 45, said channel region 49 located outwardly of said rim 48 relative to said perimeter of each said opening 45.
In an alternative embodiment, there is provided an insert component 41 to be affixed to a panel, said insert component comprising a body 42, the body 42 including a first face 43 and a second face 44, and the body 42 defining at least one opening 45 extending between the first face 43 and the second face 44, said at least one opening 45 positioned within a perimeter 46 of the body 42. A flange portion 47 is located substantially radially outwardly from one or each of said at least one opening 45. At least one rim 48 is provided upon said first face 43 and substantially about a perimeter of each said opening 45. The flange portion 47 has a relatively greater wall thickness in a region adjacent to or at said rim 48, and is of a relatively reduced wall thickness in a region adjacent to or at said perimeter 46 of said body 42.
As shown in FIGS. 16 and 19, the rim 48 may be a projection extending upwardly or in a direction away from said first face 43 and said second face 44, such that the rim 48 may be provided as a projection upstanding from said first face 43.
A height of the rim 48 may be about 2 mm, or about 3 mm, or about 4 mm, or about 5 mm, or about 6 mm, or about 7 mm, or about 8 mm, or about 9 mm, or about 10 mm, or about 11 mm, or about 12 mm, or may be less than about 12 mm, or less than about 10 mm, or less than about 8 mm, or less than about 6 mm, or less than about 4 mm, or less than about 2 mm, as measured from said first face 43 of said body 42.
As shown in FIG. 19, the channel 49 may be provided as a recess in said first face 43, and may be located between the rim 48 and said flange portion 47. The rim 48 may form a first channel wall 49A of said channel. A height of said first channel wall 49A may be substantially equal to or greater than a second channel wall 49B, and the second channel wall 49B may be located outwardly of said first channel wall 49A relative to said perimeter of each said opening. The second channel wall 49B may be located at an inner edge of the flange 47.
The channel region 49 may have a floor or base 49C defining a channel region depth, said floor or base 49C being of a level, or providing for floor or base sections of a level substantially lower than said first face 43 of said body 42 or said flange portion 47.
A depth of the channel 49 may be about 1 mm, or about 2 mm, or about 3 mm, or about 4 mm, or about 5 mm, or about 6 mm, or about 7 mm, or about 8 mm, or about 9 mm, or about 10 mm, or may be less than about 10 mm, or less than about 8 mm, or less than about 6 mm, or less than about 4 mm, or less than about 2 mm, as measured from said first face 43 of said body 42.
The channel 49 may be of a pre-determined width, said width defined between said first channel wall 49A and said second channel wall 49B.
As shown in FIG. 20, the width and/or said depth of said channel 49 may be sufficient to accommodate or receive a (curable) material M.
The width of the channel 49 may be greater than about 1 mm, or greater than about 2 mm, or greater than about 3 mm, or greater than about 4 mm, or greater than about 5 mm, or greater than about 10 mm, or greater than about 15 mm, or is about 2 mm, or is about 3 mm, or is about 4 mm, or is about 5 mm, or is about 6 mm, or is about 8 mm, or is about 10 mm, or is less than 10 mm.
The material M may be a filler material (such as, but not limited to, one or more of: a plaster-type or render-type material, such as a material comprising of gypsum, lime or cement material, or is a material capable of being decorated or may be a material which can be finished, e.g. can be sanded to a finished surface, for a subsequent application of a decorative material, such as paint).
One or more of said at least one opening 45 may further comprise of a ledge 50, said ledge 50 providing a support surface extending substantially inwardly toward a centre of said opening 45. The support surface may be a surface facing the same direction as said first face 43 of said body 42. The support surface may be a substantially planar surface, or alternatively the support surface may comprise a channel or recess. The planar surface, channel, or recess may be provided to receive a fitting or fixture as described herein. Additionally, the channel or recess of the support surface may be provided to reduce material thickness during a forming process of the insert. The support surface of said ledge 50 may be recessed from said rim 48, or may be of a reduced height relative to said rim 48. The support surface may provide a surface upon which an item is seatable, such as a light fixture or fitting, or a smoke alarm or smoke detector, or speaker, or other fittings or fixtures or devices.
The second face 44 may comprise an inner portion 51 and an outer portion 52. The outer portion 52 may substantially correspond with said flange portion 47, and the inner portion 51 may substantially correspond with said channel 49 and said rim 48.
The inner portion 51 may be a raised or stepped region, raised or stepped in a direction to accommodate said channel 49.
A sidewall 51A may define a step between said outer portion 52 and said inner portion 51, and may be provided as a guide for locating said body into an aperture of a panel.
The outer portion 52 may be substantially planar, or may comprise one or more projections, such as projections 53 in FIGS. 22 and 23, the one or more projections being of a bevelled, tapered and/or of a spiked form.
As shown in FIG. 20, the outer portion 52 may be adhered or affixed to a surface of a panel P. In one example embodiment, the one or more projections 53, as shown in FIGS. 22 and 23, may extend in a direction away from said second face 44, or in a direction toward a surface of a panel to which said insert 41 is to be affixed. The one or more projections 53 may provide for a mechanical engagement or attachment with the panel, and may be provided as an array about the second face 44 of said outer portion 52. The one or more projections 53 may provide for a temporary, or initial, or additional engagement with a panel, in combination with a curable material applied to the insert to further adhere the insert 41 to the panel. Whilst four projections 53 have been illustrated in FIG. 22, it will be understood that any number of projections may be spaced or provided in arrays on the insert 41 to provide the described initial engagement with a panel.
As for example shown in FIG. 20, an insert component 41 can be positioned partially into a rebated region R a panel P. The insert component 41 can then be mechanically affixed in place, for example by application of one or more layers of material or medium M. In an example embodiment, a first layer of material M1 may be applied, which may include using a sidewall of rim 48 as a tool guide. This layer of material may fill channel 49, which is partially recessed into the rebated region R of panel P. The apertures 49D of channel 49 may allow for excess of first material M1 to escape the channel into the space behind the insert, which may avoid the formation of air pockets within the channel. This can also provide for a greater volume of material M1 to be applied and received by the insert to assist with a greater volume of the material M1 which can ultimately be cured in place to connect with the insert.
The first material M1 may also provide for a first layer of adhesion for adhering the flange region 47 to the panel P, which may include material M1 passing through flange apertures 47A to adhere onto a surface of panel P. The first material M1 may adhere the insert 41 to the panel P, and may add strength to the panel and/or insert surrounding a fixture to be fitted. Put another way, the first material M1 may bridge or facilitate strengthening of the connection joint made between the insert 41 and the panel P.
Desirably, providing a system for strengthening the joint made between the insert and the panel may provide for a system which is capable of receiving larger or heavier items, yet avoiding or minimising the risks of break out. That is, the insert of the present disclosure may provide for an increased load factor capability relative to a traditional re-sizing of a hole which does not use the insert of this invention.
A second or finishing layer of material M2 may also be applied to the insert, which may include using the face or top of rim 48 as a tool guide. This may allow the second or finishing material M2 to be applied substantially level with the face of rim 48, whilst covering flange 47 and channel 49. Such a configuration may provide for a finished or finishable (e.g. by sanding and/or painting) surface.
In one preferred mode of installation, as shown in FIG. 20, the insert component 41 is to be positioned within a rebated region R of a panel surface P. The rebate R being of sufficient depth to at least partially accommodate the insert component 41, for example to accommodate the second portion of the second face 44. Put another way, the rebate R may be of a depth such that the second portion of the second face 44 is substantially within the rebate, whilst the ledge 50 is substantially in-line with the surface of the panel into which the insert component 41 is to be received. That is, a rebate can be formed in a face of a panel, with the rebate being of a depth to partially receive said insert, such that the flange portion 47 rests on the surface of the panel.
The flange portion 47 may have a relatively greater wall thickness in the region adjacent to or at said channel 49, and may be of a relatively reduced wall thickness in a region adjacent to or at said perimeter 46 of said body 42. In an example, the flange portion 47 may be of a wall thickness of about 0.5 mm in a region adjacent to or at said perimeter 46 of said body 42, and the flange portion 47 may be of a wall thickness of about 1 mm in a region adjacent to or at said channel 49. The flange portion 47 may be substantially tapered in a reducing wall thickness, said wall thickness reducing in a direction as said flange portion 47 extends substantially radially outwardly from said channel 49. It will be understood that the abovementioned flange portion thickness is exemplary, and the invention should be considered to incorporate any suitable flange portion thickness producing a tapered, curved, and/or angled profile.
As shown in FIG. 21, the first face 43 may comprise said rim 48 defining a first projected height H1, said flange portion 47 at or substantially adjacent to said channel 49 defining a second projected height H2, and said flange portion at or substantially adjacent to said perimeter 46 defining a third projected height H3. Each of said first H1, second H2 and third H3 projected heights may be in reference to the second face 44, or a side of the flange portion 47 on the second face 44, which may be substantially planar as illustrated in FIG. 21.
Put another way, the rim 48 may define a first projected height H1 of said first face 43, said flange portion 47 at or substantially adjacent to said channel 49 may define a second projected height H2 of said first face 43, and said flange portion 47 at or substantially adjacent to said perimeter 46 may define a third projected height H3 of said first face 43.
The third projected height H3 may be less than said second projected height H2, and the first projected height H1. Similarly, the second projected height H2 may be less than said first projected height H1. This may result in a configuration where the flange portion 47 may slope from said second projected height H2 to said third projected height H3.
The first face 43 may further comprise said support surface of said ledge 50 defining a fourth projected height (indicated as H4), and the fourth projected height may be the same, or advantageously may be less than said first projected height, or matches the height of the first projected height. In an example embodiment, the support surface of said ledge 50 may be at substantially the same height as the second face 44, or a side of the flange portion 47 on the second face 44. In such a configuration, when the insert is installed with the second face 44 (or the side of the flange portion 47 on the second face 44) substantially parallel and abutted to the panel surface, the support surface of the ledge 50 may be at substantially the same height and/or level as the surface of the panel P. Alternatively, the support surface of the ledge 50 may be positioned to as to be above or below the surface level of the panel surface or of the second face 44, or a side of the flange portion 47 on the second face 44. This may facilitate a fixture or fitting installed in the insert to be placed at a level corresponding with the panel surface P, or may be recessed from the panel surface or may project slightly beyond the panel surface as desired by aesthetics of installation.
The fourth projected height H4 may be a zero, or a positive or a negative height value with respect to the reference plane defined by the second face of the flange portion 47. That is, the support surface of the ledge 50 may be provided so as to provide for a greater height of recess relative to the projected height of the rim (being the first projected height) or may be of a smaller projected height, or may be of the same projected height as the first projected height H1 of the rim 48.
An outer edge of said flange portion 47 may define said perimeter 46 of said body 42, and the first face 43 of said outer edge may comprise a chamfered edge portion as illustrated in FIG. 21.
The flange portion 47 may extend substantially radially outwardly of said channel 49, and may extend substantially about a part, or parts, or substantially an entirety, of said perimeter 46 of said body 42. The flange portion 47 may extend continuously radially outwardly of said channel 49, or alternatively the flange portion 47 may extend as two opposing sides of said body 42 (i.e. is cut-off sides, as a radially discontinuous flange portion).
The flange portion 47 may comprise one or more apertures 47A, said apertures 47A extending through said body 42. The apertures 47A may provide for a void through said body 42, and may be distributed about said flange portion 47.
The channel 49 may comprise one or more channel apertures 49D, and said apertures 49D may extend through said body 42. The channel apertures 49D may provide for a void through said body 42, and may be distributed about said channel 49.
The channel 49 may comprise one or more ribs 49E, and the one or more ribs 49E may extend across said channel 49. The one or more ribs 49E may be strengthening members, and may provide for a strengthening structure between a wall of said rim 48 (for example channel sidewall 49A) and a wall of said flange portion 47 (for example channel sidewall 49B). The one or more ribs 49E may extend substantially across said channel 49 or said floor of said channel 49, or between sidewalls 49A/B of said channel 49. The one or more ribs 49E may be distributed about said channel 49.
The one or more ribs 49E may be of a height below the first face 43, or said one or more ribs 49E may be provided of a height recessed from said first face 43, and/or of said flange portion 47. In an example, the ribs 49E are provided as recessed ribs so as to not protrude through a curable material that may be applied to insert 41.
The body 42 may be substantially circular, oval or of a rectilinear perimeter shape. Additionally, one or more of said at least one opening(s) 45 in said body 42 may be substantially circular, oval or of a rectilinear perimeter shape, and the ledge 50 may be substantially circular, oval or of a rectilinear perimeter shape.
A diameter of an inner perimeter of said rim 48 may be about 25 mm to about 104 mm, or is about 76 mm, or about 86 mm, or about 102 mm, or about 103 mm, or about 104 mm, or about 105 mm, or about 106 mm, or may be about 160 mm, or may be about 200 mm, or is greater than about 10 mm, or greater than about 20 mm, or greater than about 25 mm, or greater than about 30 mm, or greater than about 35 mm, or greater than about 40 mm, or greater than about 50 mm, or greater than about 85 mm, or greater than about 100 mm, or greater than about 105 mm, or greater than about 125 mm, or greater than about 150 mm, or greater than about 175 mm, or greater than about 200 mm, or greater than about 300 mm, or greater than about 400 mm.
The flange 47 may be detachable or attachable or integral with said body 42. Additionally, the rim 48 or the channel 49, or both, may be detachable or attachable or integral with said body 42, and the ledge 50 may be detachable or attachable or integral with said body 42.
A separate component piece, such as a plate-type component piece as described in relation to FIG. 9, may be provided for seating upon the ledge 50. The separate component piece may be provided as a plate-type component piece comprising of one or more apertures. The separate component piece may be provided as a plug or cap for the insert component, and may be substantially planar and of a substantially constant thickness. The plate-type component piece may be provided to fill an unwanted hole in a panel, and may be arranged to receive a curable material as described herein.
As described herein, the insert 41 as defined in any of the embodiments disclosed herein may be affixed to a face of a panel. A rebate may be formed in said face of said panel, said rebate being of a depth to receive said insert 41, such that an end of said rim 48 is substantially level or aligned with said face of said panel, or an intended level of a finished or decorated surface of said panel.
A structure may be formed in-situ with a panel, and said insert 41 as defined in any of the embodiments disclosed herein may be affixed to a face of the panel, and a rebate may be formed in said face of said panel and sized so as to receive the insert such that the at least a portion at the perimeter of the body 42 is configured to extend to engage a side of the rebate and retain the insert therewithin the rebate. For example, the side wall 51A of the stepped region of the second face 44 may substantially engage with a side of the rebate, and the flange portion 47 may substantially overlap a face of the panel.
The insert as described above in relation to FIGS. 14 to 20 may be combined with any or all additional features described above. For example, the insert of the invention may further include projections or bumps on the rebate-facing face of the body so as to provide a spacing function of the body from the rebate inner surface and allow flow of adhesive and/or curable material such as plaster. Additionally, the insert may comprise one or more resilient elements or members, such as resilient member 31 in FIG. 10, arranged on a perimeter 46 of the body 42, and/or the sidewall 51A of the second face 44.
The foregoing description of the invention includes preferred forms thereof. Modifications may be made thereto without departing from the scope of the invention.

Claims

1. An insert component to be affixed to a panel, said insert component comprising:

a body, the body including a first face and a second face, the body defining at least one opening extending between the first face and the second face, said at least one opening positioned within a perimeter of the body,

a flange portion located substantially radially outwardly from one or each of said at least one opening,

at least one rim provided upon said first face and substantially about a perimeter of each said opening, and

at least one channel region provided in said first face and substantially about the perimeter of each said opening, said channel region located outwardly of said rim relative to said perimeter of each said opening.

2. The insert of claim 1, wherein said rim is a projection extending upwardly or in a direction away from said first face and said second face.

3. The insert of claim 1, wherein said rim is provided as a projection upstanding from said first face.

4. The insert of claim 1, wherein said channel is provided as a recess in said first face, and wherein said channel is located between the rim and said flange portion.

5. (canceled)

6. The insert of any preceding claim 1, wherein a height of a first wall of the channel is substantially equal to or greater than a second channel wall, the second channel wall located outwardly of said first channel wall relative to said perimeter of each said opening.

7. The insert of claim 1, wherein said channel region has a floor or base defining a channel region depth, said floor or base being of a level, or providing for floor or base sections of a level substantially lower than said first face of said body or said flange portion.

8. (canceled)

9. (canceled)

10. The insert of claim 1, wherein one or more of said at least one opening further comprises of a ledge, said ledge providing a support surface extending substantially inwardly toward a centre of said opening, and wherein said support surface is a surface facing the same direction as said first face of said body.

11. (canceled)

12. The insert of claim 10, wherein said support surface is a substantially planar surface, or wherein said support surface comprises a channel or recess.

13. (canceled)

14. The insert of claim 10, wherein said support surface of said ledge is recessed from said rim, or is of a reduced height relative to said rim.

15. (canceled)

16. (canceled)

17. The insert of claim 1, wherein said second face comprises an inner portion and an outer portion, and wherein said outer portion substantially corresponds with said flange portion, and wherein said inner portion substantially corresponds with said channel and said rim.

18. (canceled)

19. The insert of claim 17, wherein said inner portion is a raised or stepped region, raised or stepped in a direction to accommodate said channel, and wherein a sidewall defining a step between said outer portion and said inner portion is provided as a guide for locating said body into an aperture of a panel.

20. (canceled)

21. The insert of claim 17, wherein said outer portion is substantially planar, or wherein said outer portion comprises one or more projections, the one or more projections is/are of a bevelled, tapered and/or of spiked form, wherein said one or more projections extend in a direction away from said second face, or in a direction toward a surface of a panel to which said insert is to be affixed.

22. The insert of claim 17, wherein said outer portion comprises of an adhesive, in use to be adhered or affixed to a surface of a panel.

23. (canceled)

24. (canceled)

25. The insert of claim 1, wherein said flange portion has a relatively greater wall thickness in the region adjacent to or at said channel, and is of a relatively reduced wall thickness in a region adjacent to or at said perimeter of said body, and wherein said flange portion is substantially tapered in a reducing wall thickness, said wall thickness reducing in a direction as said flange portion extends substantially radially outwardly from said channel.

26. (canceled)

27. The insert of claim 1, wherein said first face comprises said rim defining a first projected height, said flange portion at or substantially adjacent to said channel defining a second projected height, and said flange portion at or substantially adjacent to said perimeter defining a third projected height, and wherein said third projected height is less than said second projected height, and said second projected height is less than said first projected height.

28-31. (canceled)

32. The insert of claim 27, wherein said flange portion slopes from said first or second projected height to said third projected height.

33. The insert of claim 1, wherein an outer edge of said flange portion defines said perimeter of said body, and wherein the first face of said outer edge comprises a chamfered edge portion.

34. (canceled)

35. The insert of claim 27, wherein said first face further comprises said support surface of said ledge defining a fourth projected height, and wherein said fourth projected height is less than said first projected height, or matches the height of the first projected height.

36. (canceled)

37. The insert of claim 1, wherein said flange portion extends substantially radially outwardly of said channel, and wherein said flange portion extends substantially about a part, or parts, or substantially an entirety, of said perimeter of said body.

38. (canceled)

39. The insert of claim 1, wherein said flange portion extends as two opposing sides of said body, or wherein two opposing sides of said flange portion are substantially parallel.

40. The insert of claim 1, wherein said flange portion comprises one or more apertures, said apertures extending through said body, and wherein said apertures are distributed about said flange portion.

41. (canceled)

42. The insert of claim 1, wherein said channel comprises one or more channel apertures, said apertures extending through said body, and wherein said channel apertures are distributed about said channel.

43. (canceled)

44. The insert of claim 1, wherein said channel comprises one or more ribs, and wherein the one or more ribs extend across said channel.

45. (canceled)

46. The insert of claim 1, wherein said body and one or more of said at least one opening(s) are substantially circular, oval or of a rectilinear perimeter shape.

47. (canceled)

48. The insert of claim 1, wherein one or more of the: said flange portion, said rim, said channel, said ledge is/are detachable or attachable or integral with said body.

49-50. (cancelled).

51. A structure formed in-situ with a panel, wherein said insert as defined in claim 1 is affixed to a face of the panel, and

wherein a rebate is formed in said face of said panel and sized so as to receive the insert such that the at least a portion of the body is configured to recess into the rebate and/or engage a side of the rebate and locate and/or retain the insert therewithin the rebate.

52. An insert component to be affixed to a panel, said insert component comprising:

wherein said flange portion has a relatively greater wall thickness in a region adjacent to or at said rim, and is of a relatively reduced wall thickness in a region adjacent to or at said perimeter of said body.