WO2023118835A1

WO2023118835A1 - An apparatus for receiving an access panel and/or an access panel frame into a wall and a method of installation of the same

Info

Publication number: WO2023118835A1
Application number: PCT/GB2022/053299
Authority: WO
Inventors: Simon ALLERTON
Original assignee: Era Home Security Limited
Priority date: 2021-12-21
Filing date: 2022-12-20
Publication date: 2023-06-29
Also published as: GB2614065A

Abstract

An apparatus 1 for receiving an access panel and/or an access panel frame into a wall (300, Fig. 7) comprises a support structure 100 comprising a plurality of elongate members (110a, 110b, 120a, 120b) arranged to define a square or rectangular opening (130). Each of the elongate members (110a, 110b, 120a, 120b) forms a respective edge of the opening (120). The apparatus (1) further comprises an intermediate frame (200) defining an aperture (230) for receiving the access panel and/or the access panel frame. The intermediate frame (200) is shaped and dimensioned to match the internal dimensions of the opening (130) of the support structure (100). The intermediate frame (200) is secured to the support structure (100) and positioned within the opening (130). The intermediate frame (200) comprises one or more flanges (212, Fig. 4), each flange (212, Fig. 4) being parallel to a corresponding elongate member (110a, 110b, 120a, 120b) and arranged to define a channel (150, Fig. 5B) between the flange (212, Fig. 4) and the corresponding elongate member (110a, 110b, 120a, 120b) for receiving one or more sheets (310a, 310b, 310c, Fig. 5C) of wall material.

Description

AN APPARATUS FOR RECEIVING AN ACCESS PANEL AND/OR AN ACCESS PANEL FRAME INTO A

WALL AND A METHOD OF INSTALLATION OF THE SAME

The present disclosure relates to an apparatus for receiving an access panel and/or an access panel frame into a wall, an associated kit of parts, and method of installation

5 thereof.

Access panels are used to provide closable access to a concealed item or region. They are commonly used in buildings to protect and provide access to, for example, plumbing or electrical equipment. Access panels typically comprise a frame and a door

10 or a cover. The door is secured to the frame, and the frame is installed within an opening in, for example, a wall, ceiling or floor. The frame and the door collectively close the opening to prevent the spread of fire and/or smoke through the opening. The frame and the door may also close the opening to prevent people gaining access to the concealed item or region.

15

During construction of a wall, in particular a stud wall for defining a shaft in a building, it is common to install an access panel in the wall to provide access between the two sides of the wall. The access panel is received by an opening within the wall. The wall is often constructed using studs and these studs may be arranged to define the

20 opening to receive the access panel. In order for construction workers to correctly size and shape the opening, the door and frame of the access panel are delivered to a building site before the wall is constructed. The construction workers can measure the dimensions of the access panel and thereby arrange the studs to form an opening with the correct dimensions to receive the access panel.

25

Such a method of constructing a wall has several problems. Firstly, the provision of the access panel during construction means that the access panel is more likely to be damaged on site, before it is even required for installation. Secondly, since studs are used to define the opening for receiving the access panel, the access panel must be

30 installed during construction of the wall, while the studs are accessible. This further increases the likelihood of damage or wear-and-tear to the access panel, since it is installed before the building is nearing completion. Finally, this construction method requires highly accurate and precise measurement by the construction workers to ensure that the entire wall is built in such a way that the access panel can be

35 adequately received. If the opening is too small, the access panel will not fit and cannot be installed. If the opening is too large, fire resistance or heat retention is lost by gaps between the access panel and the opening.

The present invention seeks to address the aforementioned problems.

Summary

According to a first aspect of the present disclosure, there is provided an apparatus for receiving an access panel and/or an access panel frame into a wall, as defined in claim 1.

The apparatus comprises a support structure comprising a plurality of elongate members arranged to define a square or rectangular opening. Each of the elongate members forms a respective edge of the opening. The apparatus further comprises an intermediate frame defining an aperture for receiving the access panel and/or the access panel frame. The intermediate frame is shaped and dimensioned to match the internal dimensions of the opening of the support structure. The intermediate frame is secured to the support structure and positioned within the opening. The intermediate frame comprises one or more flanges. Each flange is parallel to a corresponding elongate member and arranged to define a channel between the flange and the corresponding elongate member for receiving one or more sheets of wall material. The term ‘corresponding’ as used herein may refer to a flange, elongate member, edge, channel, or other similar component and is used to imply that the corresponding features are associated with one another, for example, by way of their position relative to one another. In this context, the term ‘match’ means that the shape and dimensions of the intermediate frame are substantially equal to the shape and dimensions of the opening; however, the dimensions need not be exactly equal in order to accommodate manufacturing tolerances in the intermediate frame and/or construction tolerances in the opening, and to allow sufficient clearance for the intermediate frame to be positioned within the opening.

Advantageously, by providing a channel for receiving sheets of wall material, the apparatus may be installed prior to, or during, the construction of the surrounding wall, with the sheets of wall material being added after installation of the apparatus. This allows the wall to be constructed with a pre-dimensioned aperture, into which an access panel and/or an access panel frame can be received after the wall is constructed. Furthermore, this advantageously allows the wall to be constructed without the access panel and/or access panel frame being present on the construction site. This reduces the risk of damage to the access panel and/or access panel frame on the construction site, since the access panel and/or access panel frame can be delivered to site towards the end of construction.

The access panel may be a door, window, cover, or any other substantially planar component that is suitable to close an opening within the access panel frame. The access panel may be a riser door. In such a case, the access panel frame may be a riser door frame. The apparatus (and, more specifically, the aperture) may directly receive an access panel without an access panel frame. For example, the intermediate frame may act as an access panel frame for receiving the access panel directly. Alternatively, the apparatus (and, more specifically, the aperture) may receive an access panel frame without an access panel already attached. For example, the access panel frame may be configured to attach to an access panel after installation of the access panel frame. Alternatively, the apparatus (and, more specifically, the aperture) may receive an access panel frame that has an access panel frame already attached. In this way, the apparatus is for receiving an access panel and/or an access panel frame into a wall.

The term ‘wall’ is used herein as reference to a planar structure that typically extends substantially vertically between a ceiling and a floor. However, it will be understood that the apparatus, kit, and method as described herein may equivalently be applied to a ceiling, floor, partition, or other similar planar structure. The wall may, for example, be a partition wall for defining a shaft or duct. Such walls may commonly be referred to as ‘shaft walls’.

The plurality of elongate members may comprise one or more first elongate members and one or more second elongate members. The first elongate members may be considered to be horizontal elongate members. The second elongate members may be considered to be vertical elongate members. By ‘horizontal’, it is meant that, when the apparatus is installed into a wall, the elongate members extend substantially parallel to the floor and ceiling. By ‘vertical’, it is meant that, when the apparatus is installed into a wall, the elongate members extend substantially perpendicular to the floor and ceiling. It will be appreciated that, instead, the first elongate members may be considered to be vertical elongate members and the second elongate members may be considered to be horizontal elongate members, depending on the orientation of the apparatus.

For example, the plurality of elongate members may comprise two first (e.g. horizontal) elongate members and two second (e.g. vertical) elongate members. The vertical distance between the two first elongate members may define the height of the opening. The horizontal distance between the two second elongate members may define the width of the opening. In this way, the first and second elongate members may define four edges of the opening. Advantageously, the presence of two first elongate members and two second elongate members provides increased structural integrity to the apparatus, by providing support to all four of the edges of the opening. This is contrast to, for example, a standard door frame which comprises only three elongate members and lacks an elongate member at the bottom of the opening.

The intermediate frame may be a single unitary component. For example, the intermediate frame may be manufactured by welding, extrusion, or additive manufacturing processes to form a single unitary intermediate frame. Alternatively, the intermediate frame may comprise a plurality of strips that can be arranged to form the intermediate frame. Each strip may form an edge of the intermediate frame. The strips may be capping strips. The strips may be secured to each other to form an intermediate frame. Alternatively, securing each of the strips to the support structure may form the intermediate frame.

The intermediate frame (e.g. the strips) may be secured to the support structure at, or close to, the edges of the opening. The intermediate frame may be secured to the support structure by adhesive, mechanical fasteners (such as screws), an interference fit, or any other suitable securing method.

The one or more flanges may extend from the intermediate frame in a direction parallel to a plane of the opening. In other words, the one or more flanges may extend in a direction parallel to the plane of the wall, when the apparatus is installed. Each flange may be spaced from the corresponding elongate member in a direction perpendicular to the plane of the opening. The space between each flange and the corresponding elongate member may define the channel for receiving the one or more sheets of wall material. The space between each flange and the corresponding elongate member may be considered to be the width of the channel. The width of the channel determines the thickness and/or number of sheets of wall material that may be received by the channel.

The channel may be parallel to the corresponding elongate member. The channel may have a length that is the same as the length of the corresponding elongate member. In such a case, it will be understood that the corresponding flange also has the same length as the channel and the corresponding elongate member. Alternatively, the flange may span only part of the length of the corresponding elongate member, thereby defining a channel with a length that is only part of the length of the corresponding elongate member.

The one or more sheets of wall material may be received in the channel by being positioned in the channel during installation of the apparatus. The positioning may comprise sliding the one or more sheets in a direction parallel to the plane of the opening (i.e. parallel to the wall). The sliding may be in a direction parallel to the length of the channel (i.e. each sheet may be received by an opening at an end of the channel and then slid along the length of the channel). Alternatively or additionally, the sliding may be in a direction perpendicular to the length of the channel (i.e. each sheet may be slid into the depth of the channel).

The channel may be configured to hold and/or support the one or more sheets of wall material. By ‘holding’ it is meant that the one or more sheets are held in place so that they do not fall away from the plane of the wall during installation of the apparatus and construction of the wall. By ‘supporting’ it is meant that the channel provides structural support sufficient to maintain the integrity of the sheets when the wall is constructed.

The one or more sheets of wall material may comprise panels, plasterboard (also known as drywall or gypsum board), or other sheets of materials commonly known for forming walls. Such materials are known to include wood, plaster, and metal, but any other similar materials suitable for forming a wall may be used. The apparatus may further comprise the one or more sheets of wall material. The wall may further be formed of support beams, commonly known as ‘studs’ or ‘wall studs’. The apparatus may further comprise the support beams/studs/wall studs. The apparatus may comprise the wall. It will be understood that the apparatus comprising the wall means that the apparatus comprises the one or more sheets of wall material and the support beams.

The apparatus may further comprise a plurality of brackets, each bracket for securing a corresponding elongate member to a floor and/or ceiling of a building into which the apparatus is to be installed. The brackets may be L-shaped and may comprise a securing means (such as screw holes or other mechanical fastening means known in the art) for securing the brackets to the elongate members and/or to the floor and/or ceiling.

In some embodiments, the intermediate frame comprises a first flange and a second flange. The intermediate frame may further comprise a bridging member connecting the first flange to the second flange. The first flange may be arranged to define the channel between the first flange and a first sidewall of the corresponding elongate member. The bridging member may be arranged to extend through the opening towards a second sidewall of the corresponding elongate member. The second flange may be arranged to abut the second sidewall of the corresponding elongate member.

Advantageously, the presence of a second flange allows the intermediate frame to hold onto the corresponding elongate member without additional securing means present. In other words, the second flange prevents the intermediate frame from falling away from the opening in a direction towards the first flange, without the need for securing (e.g. screwing the intermediate frame to the support structure). Furthermore, if the depth of the elongate member is known, the depth of the bridging member (and thus the space between the first flange and the second flange) may be chosen to be greater than the depth of the elongate member by such an amount so as to define a certain thickness of the channel. For example, by increasing the distance between the first and second flanges, the space between the first flange and the corresponding elongate member is increased, thereby increasing the width of the channel and allowing the channel to receive wider, and/or more, sheets of wall material. Similarly, the distance between the first and second flanges may be decreased to allow the channel to receive narrower, and/or fewer, sheets of wall material. It is contemplated that the intermediate frame may alternatively comprise only a single (e.g. first) flange arranged to define the channel, without the presence of a (e.g. second) flange abutting the second sidewall of the corresponding elongate member.

The first sidewall of the elongate member may correspond to a front sidewall of the support structure and the second sidewall of the elongate member may correspond to a rear sidewall of the support structure. It will be appreciated that, since access panels can be accessed from either direction, the terms ‘rear’ and ‘front’ are interchangeable. In cases where the access panel can only be accessed from a single direction (for example, for access to a cupboard or shaft), the term ‘rear’ refers to the side on which the area to be accessed is located and the term ‘front’ refers to the side from which, typically, the access panel will be accessed.

In some embodiments, one or more of the flanges of the intermediate frame comprise beading for receiving liquid plaster.

Advantageously, providing beading directly on the intermediate frame allows liquid plaster to be applied directly to the apparatus during installation and during construction of the wall. This allows construction of the wall to be substantially completed prior to installation of the access panel and/or the access panel frame. As described above, this means that the wall can be completed before the access panel and/or the access panel frame are delivered to the construction site, thus reducing the risk of damage to the access panel and/or the access panel frame on the construction site.

The beading may comprise a plurality of perforations through the flange (e.g. the first flange). The beading may be suitable for receiving any other suitable liquid construction materials, such as paint or glue.

In some embodiments, the apparatus further comprises a connection mechanism. The connection mechanism may be configured to, upon insertion of the access panel and/or the access panel frame into the aperture of the intermediate frame, connect the access panel and/or the access panel frame to the intermediate frame. Advantageously, a connection mechanism that connects the access panel and/or the access panel frame to the intermediate frame upon insertion improves the ease and speed with which the access panel and/or the access panel frame can be installed. Furthermore, it reduces or completely removes the need for any further tools or fixing components. That is, the access panel and/or the access panel frame may simply be placed into the aperture, at which point the panel and/or the frame is connected to the intermediate frame.

The connection arrangement may comprise a plurality of holes located on an outer edge of the access panel and/or the access panel frame and a plurality of biased pins located on the edge of the aperture of the intermediate frame. The biased pins may be biased into an extended position and depressable into a contracted position. When the biased pins are depressed into the contracted position, the access panel and/or the access panel frame may be inserted into the intermediate frame, at which point the biased pins are aligned with the holes and may then extend through the holes and into the extended position, thereby connecting the access panel and/or the access panel frame to the intermediate frame. The biased pins may comprise one or more springs configured to bias the pins into the extended position.

Alternatively, the connection arrangement may comprise a snap-fit arrangement. The snap-fit arrangement may comprise an arrangement of flexible tabs on the intermediate panel which flex to receive the access panel and/or the access panel frame and then return to an initial position to prevent removal of the access panel and/or the access panel frame.

Alternatively, the connection arrangement may comprise an interference fit between the intermediate frame and the access panel and/or the access panel frame. In other words, the fit between the intermediate frame and the access panel and/or the access panel frame is such that friction between these components is sufficient to prevent subsequent removal of the access panel and/or the access panel frame.

In some embodiments, each of the elongate members comprises a sidewall extending along the length of the elongate member. The sidewall may protrude in a direction parallel to a plane of the opening. Each elongate member may further comprise an elongate lip extending along the length of the elongate member. The elongate lip may protrude in a direction perpendicular to the plane of the opening. For each elongate member, the sidewall, the elongate lip, and a corresponding flange may define the channel for receiving the one or more sheets of wall material.

The elongate lip may be considered a first elongate lip and each elongate member may further comprise a second elongate lip extending along the length of the elongate member. The second elongate lip may protrude in a direction opposite to the first elongate lip. For example, the first elongate lip may protrude away (e.g. forwardly) from the first (e.g. front) side of the elongate member and the second lip may protrude away (e.g. rearwardly) from the second (e.g. rear) side of the elongate member.

In such embodiments, and when the intermediate frame comprises a second flange, the second flange may be arranged to define a second channel between a second sidewall of the elongate member, the second elongate lip, and the second flange. The characteristics, features, and advantages discussed with reference to the aforementioned channel (which may be considered a first channel) equivalently apply to the second channel.

Advantageously, the presence of a second lip (and, optionally, the second flange) allows one or more sheets of wall material to be received on the second (e.g. rear) side of the elongate members. This allows a wall to be constructed symmetrically about the plane of the wall, i.e. with wall material disposed on both sides of the wall.

The second flange may protrude from the elongate member by a distance less than the first flange protrudes. Advantageously, this allows more and/or thicker sheets of wall material to be provided in the first channel and fewer and/or thinner sheets of material to be provided in the second channel. This may be useful, for example, where the wall is a partition wall for defining a shaft. In such a case, it may be preferred to build an aesthetically and/or structurally stronger wall on one side (e.g. on the side outside of the shaft) and only a loosely covered wall on the other side (e.g. on the side inside of the shaft).

In some embodiments, each elongate member comprises a portion having a U-shaped or box-shaped cross-section portion. The shape of the cross-section may be defined one or sidewalls of the elongate member. For example, an elongate member comprising three sidewalls may be arranged to define a U-shaped cross section. An elongate member comprising four sidewalls may be arranged to define a box-shaped cross-section. Advantageously, the space defined by the U-shaped or box-shaped cross-section can be used to receive a material with fire resistant and/or insulating properties. In such embodiments, the apparatus may further comprise the material disposed within a space defined by the U- shaped or box-shaped cross-section. The material may be used to improve the fire resistance of the wall. Alternatively or additionally, the material may improve the heat retention of the wall.

In some embodiments, the plurality of elongate members comprises one or more first elongate members arranged to provide horizontal edges of the opening when the apparatus is installed. The plurality of elongate members may further comprise one or more second elongate members arranged to provide vertical edges of the opening when the apparatus is installed.

In this way, the first elongate members define the width of the opening. The second elongate members define the height of the opening. It will, however, be appreciated that the length of the first and second elongate members is not necessarily the same as the width and height of the opening, since the elongate members may extend past the opening.

In some embodiments, the first elongate members are manufactured from a first sheet material and the second elongate members are manufactured from a second sheet material. The first sheet material may be of greater thickness than the second sheet material.

Advantageously, this provides the first (e.g. horizontal) elongate members with greater strength and structural integrity than the second (e.g. vertical) elongate members. Furthermore, this allows the second elongate members to be thin enough so as to be cut to a required length during construction, whereas the first elongate members may be too thick to be easily cut, but will provide greater strength. In particular, it may be advantageous, for example, for the vertical elongate members to be provided deliberately too long for installation and so they may be cut to the correct length on site. In contrast, the horizontal elongate members may be provided at the correct length for the necessary width of the opening and so they do not need cutting. When installed, the horizontal elongate members may be placed such that they may be under-foot (e.g. at the base of the opening) and so are prone to being trodden on during construction. It is therefore advantageous for the horizontal elongate members to be constructed of thicker material so as to be less prone to bending when trodden on.

For example, the first sheet material may have a thickness between 0.5 mm and 1 mm, and in particular, 0.9 mm. The second sheet material may have a thickness of between 1.5 mm and 3 mm, and in particular, 2 mm. The first sheet material and the second sheet material may comprise the same material or a different material. The first sheet material and/or the second sheet material may comprise metal, for example, steel.

In some embodiments, the first elongate members are longer than the second elongate members.

As described above, the second (e.g. vertical) elongate members may be provided too long for installation into a building. For example, the second elongate members may be longer than the typical floor-to-ceiling height of a building. For example, the second elongate members may have a length between 2.5 m and 3.5 m. The first (e.g. horizontal) elongate members may be provided to a length suitable for a standard opening for receiving an access panel and/or access panel frame. For example, the first elongate members may have a length between 1 m and 1.5 m.

In some embodiments, each of the first elongate members comprises a tab at each end of the first elongate member. Each second elongate member may comprise a slot. Each tab may be inserted into a respective slot to join each first elongate member to a respective second elongate member.

In some embodiments, the slot may be positioned along the length of a second elongate member so as to define a dimension of the opening.

More specifically, the slot may be positioned along the length of the second elongate member so as to define a height of the opening. For example, the length of the second elongate member may correspond to the floor-to-ceiling distance and the position of the slot on the second elongate member may define the height of the opening. It will, however, be appreciated that the slots and tabs may be reversed (i.e. each first elongate member may comprise a slot and each second elongate member may comprise a tab) such that the location of the slots defines the width of the opening.

Advantageously, the presence of a slot positioned on one of the elongate members for receiving a tab on another elongate members allows the elongate members to be joined to one another so as to form an opening with predetermined dimensions. In other words, the location of the slot defines a dimension of the opening since it determines the location at which another elongate member is joined. A tab-and-slot arrangement ensures that the elongate members are joined to define particular dimensions of the opening. That is, the tabs and slots can be positioned such that, when the support structure is assembled, the opening is formed with dimensions that accurately correspond to those of the access panel and/or access panel frame. This ensures that, upon installation, the access panel and/or access panel frame will fit within the opening without gaps. This also reduces the possibility of error when the support structure is assembled, in contrast to, for example, joining the elongate members by screws and screw holes, which may be drilled based on inaccurate measurements taken on the construction site.

Furthermore, advantageously, the use of slots and tabs avoids the need for a separate bracket to join the elongate members to one another. This further simplifies installation, since fewer components are required to join the elongate members.

Further still, the use of slots and tabs allows the support structure to be constructed on site, rather than requiring delivery as a single unitary structure. This facilitates easier storage and transportation of the support structure prior to installation.

In some embodiments, the tabs are flexible so as to allow them to be bent. Bending the tabs after they have been inserted into the slots secures the first elongate member to the second elongate member.

Advantageously, this allows the elongate members to be secured to one another without further components (e.g. screws). However, the tabs may further comprise screw holes for receiving screws through the tabs and into the second elongate member once the tabs have been bent. Advantageously, this provides further structural support to the join between the elongate members and prevents the tabs being inadvertently removed from the slots after installation.

In some embodiments, the plurality of elongate members are integrally formed with one another to form the support structure.

Advantageously, integrally forming the support structure allows the support structure to be pre-dimensioned to receive an access panel and/or access panel frame of known shape and dimensions. For example, the support structure may be manufactured by welding, extrusion, or an additive manufacturing process to form a single unitary support structure.

In some embodiments, the apparatus further comprises an access panel and/or an access panel frame. The intermediate frame may be shaped and dimensioned such that the aperture matches the shape and dimensions of the access panel and/or the access panel frame. In this context, the term ‘match’ means that the shape and dimensions of the aperture of the intermediate frame are substantially equal to shape and dimensions of the access panel and/or the access panel frame; however, the dimensions need not be exactly equal in order to accommodate manufacturing tolerances in any or all of the intermediate frame, access panel or access panel frame, and to allow sufficient clearance for the access panel and/or access panel frame to be positioned within the aperture.

In known methods of installing a wall with an access panel and/or access panel frame, components are assembled on site by cutting wall studs to an appropriate length. This requires that the wall studs are made of thin material to allow them to be cut. It also places a burden on construction workers to accurately measure and cut the wall studs to ensure that the access panel and/or the access panel frame can be received by an opening in the wall. By pre-dimensioning the support structure, the elongate members can be manufactured of thicker and stronger material, since they do not need to be cut during installation. Furthermore, there is no reliance on the accurate measurement and cutting of wall studs during installation. According to a second aspect of the present disclosure, there is provided a kit of parts, as defined in claim 15.

The kit of parts comprises a plurality of elongate members configured to be arranged to form a support structure that defines a square or rectangular opening such that each of the elongate members forms a respective edge of the opening. The kit of parts further comprises one or more strips securable to the support structure within the opening to form an intermediate frame that defines an aperture for receiving an access panel and/or an access panel frame. The one or more strips are dimensioned such that, when the one or more strips are secured to the support structure, the intermediate frame is shaped and dimensioned to match the internal dimensions of the opening of the support structure. The one or more strips comprise one or more flanges such that, when the one or more strips are secured to the edges of the opening, each flange is parallel to a corresponding elongate member and arranged to define a channel between the flange and the corresponding elongate member for receiving one or more sheets of wall material.

The aforementioned features, characteristics, and advantages described with respect to the apparatus may equivalently be applied to the kit of parts as described herein. Furthermore, the provision of a kit of parts advantageously provides for easier transportation and storage of the components of the apparatus prior to installation of the apparatus.

In some embodiments, the one or more strips are pre-assembled to form an intermediate frame being securable to the support structure within the opening.

In some embodiments, the kit of parts further comprises an access panel and/or an access panel frame. The one or more strips may be shaped and dimensioned such that, when assembled into an intermediate frame, the aperture matches the shape and dimensions of the access panel and/or the access panel frame.

According to a third aspect of the present disclosure, there is provided a method of installation of the apparatus as described herein, as defined in claim 18. The method comprises securing one or more of the elongate members to a floor and/or a ceiling of a building into which the apparatus is to be installed. The method further comprises positioning the intermediate frame in the opening. The method further comprises securing the intermediate frame to the support structure. The method further comprises positioning one or more sheets of wall material such that the one or more sheets are received by the channels defined between one or more flanges and corresponding elongate members.

The aforementioned features, characteristics, and advantages described with respect to the apparatus and the kit of parts may equivalently be applied to the method as described herein.

In some embodiments, the method further comprises arranging the plurality of elongate members to form the support structure such that each of the elongate members forms a respective edge of the square or rectangular opening in the support structure. Arranging the plurality of elongate members may occur prior to securing one or more of the elongate members to the floor and/or ceiling.

In some embodiments, arranging the plurality of elongate members comprises inserting a tab of a first elongate member into a slot of a second elongate member. Arranging the plurality of elongate members may further comprise bending the tab in order to secure the first elongate member to the second elongate member.

In some embodiments, the method further comprises attaching one or more wall studs to the support structure to define a stud wall structure including the support structure. Attaching the one or more wall studs to the support structure may occur prior to positioning the one or more sheets of wall material.

Attaching the one or more wall studs to the support structure may occur prior to or after securing the intermediate frame to the support structure.

In some embodiments, positioning the intermediate frame in the opening comprises inserting one or more strips into the opening. Securing the intermediate frame to the support structure may comprise securing each of the strips to a respective elongate member. In some embodiments, the method further comprises inserting the access panel and/or the access panel frame into the aperture of the intermediate frame. The method may further comprise connecting the access panel and/or the access panel frame to the intermediate frame.

Connecting the access panel and/or the access panel frame may be the final process performed as part of the method. For example, the access panel and/or the access panel frame may be connected after construction of the wall has been substantially completed.

The method may further comprise applying liquid plaster to a beading located on the one or more flanges of the intermediate frame. Applying liquid plaster to the beading may occur prior to connecting the access panel and/or the access panel frame.

Brief Description of the Figures

Embodiments will be described, by way of example only, with reference to the Figures, in which:

Figure 1A is a perspective view of an apparatus for receiving an access panel and/or an access panel frame into a wall;

Figure 1 B is a perspective view of the apparatus of Figure 1A with an intermediate frame of the apparatus removed from a support structure of the apparatus;

Figure 2 is a perspective view of a first elongate member that forms part of the support structure;

Figure 3A is a close-up perspective view of a tab-and-slot arrangement of a first elongate member and a second elongate member, before the tabs have been inserted into the slots;

Figure 3B is a close-up perspective view of the tab-and-slot arrangement, after the tabs have been inserted into the slots;

Figure 4 is a perspective view of a strip that forms part of the intermediate frame; Figure 5A is a top view of a second elongate member that forms part of the support structure;

Figure 5B is a top view of the second elongate member with a strip of the intermediate frame secured to the second elongate member to define a channel;

Figure 5C is a top view of the second elongate member and the strip, with sheets of wall material positioned within the channel;

Figure 6 is a close-up perspective view of the sheets of wall material positioned within the channel;

Figure 7 is a perspective view of the apparatus of Figure 1A installed in a wall; and

Figure 8 shows a method of installation of an apparatus for receiving an access panel and/or an access panel frame into a wall.

Detailed Description

Figures 1A and 1B depict an apparatus 1 for receiving an access panel and/or an access panel frame. The apparatus 1 comprises a support structure 100 and an intermediate frame 200. In particular, Figure 1A depicts the apparatus 1 when the intermediate frame 200 is secured to the support structure 100, and Figure 1B depicts the apparatus 1 with the intermediate frame 200 removed from the support structure 100.

It will be appreciated that the apparatus 1 may be for receiving either an access panel or an access panel frame. The access panel frame may or may not have an access panel already fitted at the time it is received by the apparatus 1. Any reference to an ‘access panel’ as used herein will be taken to refer equivalently to an access panel frame, and vice versa.

The support structure 100 comprises a plurality of (in this case, four) elongate members 110a, 110b, 120a, 120b arranged to define an opening 130. Each of the elongate members 110a, 110b, 120a, 120b forms a respective edge of the opening 130. The opening 130 is shown to be rectangular in the Figures, but may take on any appropriate shape depending on the particular purpose. The intermediate frame 200 comprises a plurality of (in this case, four) strips 210a-d arranged to define an aperture 230 for receiving an access panel. Each of the strips 210a-d forms a respective edge of the aperture 230. The intermediate frame 200 is (and, more specifically, the strips 210a-d are) dimensioned to match the internal dimensions of the opening 130 of the support structure 100. In Figure 1A, the intermediate frame 200 is secured to the support structure 100 and positioned within the opening 130.

The apparatus 1 further comprises a plurality of (in this case, four) brackets 140a-d for securing the elongate members 120a, 120b to a floor and/or ceiling of a building into which the apparatus 1 is to be installed. More specifically, brackets 140a, 140b are for securing elongate members 120a, 120b to the ceiling and brackets 140c, 140d are for securing elongate member 120a, 120b to the floor.

The support structure 100 and the intermediate frame 200 will now be described in detail with respect to Figures 2-4.

In particular, the support structure 100 comprises a plurality of (in this case, two) first elongate members 110a, 110b and a plurality (in this case, two) second elongate members 120a, 120b. The first elongate members 110a, 110b may be considered horizontal elongate members 110a, 110b as they are arranged to be horizontal when the apparatus 1 is installed in a wall (see Figure 7). The second elongate members 120a, 120b may be considered vertical elongate members 120a, 120b as they are arranged to be vertical when the apparatus 1 is installed in a wall (see Figure 7). It will, however, be appreciated that the terms ‘horizontal’ and ‘vertical’ are not considered to be structurally limiting and the elongate members 110a, 110b, 120a, 120b may take on substantially any orientation depending on the particular purpose.

The horizontal elongate member 110a is depicted in Figure 2. The horizontal elongate member 110a comprises a substantially U-shaped cross-section. The U-shaped crosssection is defined by a first sidewall 112, a second sidewall 114, and a third sidewall 116, which are arranged to define a U-shape with an enclosed space 117. The horizontal elongate member 110a may, in some embodiments, comprise a substantially box-shaped cross-section. In such embodiments, the horizontal elongate member 110a may comprise a fourth sidewall (not shown) defined parallel to the third sidewall 116. The space 117 defined by the horizontal elongate member 110a may be filled with a material with fire resistant and/or insulating properties, such that the apparatus 1 provides improved fire resistance and/or heat retention when installed in a wall.

The horizontal elongate member 110a further comprises a first elongate lip 118 extending along the length of the horizontal elongate member 110a and protruding in a direction parallel to the third sidewall 116. When the support structure 100 is assembled, the first elongate lip 118 is arranged to protrude in a direction perpendicular to the plane of the opening 130. The horizontal elongate member 110a may, in some embodiments, optionally further comprise a second elongate lip 119 (shown by dashed lines) that extends along the length of the horizontal elongate member 110a and protrudes in a direction parallel to the third sidewall 116 but opposite to the direction of the first elongate lip 118. In such embodiments, the first elongate lip 118 and the second elongate lip 119 protrude from opposing sides of the opening 130. A second elongate lip 129 for a vertical elongate member 120a is also shown in Figure 5A (see below).

As more clearly shown with respect to a vertical elongate member 120a in Figures 5A- 5C, the plurality of elongate members 110a, 110b, 120a, 120b may be formed by bending a sheet material (such as a sheet metal), for example, using a brake press, as is known in the art. Alternatively, the elongate members 110a, 110b, 120a, 120b may be manufactured using other known methods such as extrusion or additive manufacturing processes.

The horizontal elongate member 110a further comprises a plurality of (in this case, four) tabs 111a-d. Each tab 11a-d is located at an end of the horizontal elongate member 110a and protrudes in a direction parallel to the elongate direction of the horizontal elongate member 110a. The purpose of the tabs 111a-d will be described in detail below with reference to Figures 3A and 3B.

Figure 3A depicts the horizontal elongate member 110a prior to being secured to the vertical elongate member 120a. The tabs 111a, 111b on the horizontal elongate member 110a are shown in a first position, prior to being bent. The vertical elongate member 120a comprises two corresponding slots 121a, 121b which are shaped, spaced, and dimensioned so as to be able to receive the tabs 111a, 111b on the horizontal elongate member 110a. To secure the horizontal elongate member 110a to the vertical elongate member 120a, the tabs 111a, 111b are each inserted into a respective slot 121a, 121b. The tabs 111a, 111b are then bent ‘upwards’ or ‘downwards’ (relative to the view in Figures 3A and 3B) to prevent the tabs 111a, 111b from being removed from the slots 121a, 121b, as shown in Figure 3B. Screws (or other known mechanical fastening means) may also be inserted into screw holes 111a’, 111b’ in the tabs 111a, 111b to further secure the elongate members 110a, 120a together.

While Figures 2, 3A, and 3B depict the particular horizontal elongate member 110a and particular vertical elongate member 120a, it will be appreciated that the features, characteristics, and advantages may be applied to the remaining horizontal and vertical elongate members. Furthermore, the features, characteristics, and advantages of the horizontal elongate members 110a, 110b may equivalently apply to the vertical elongate members 120a, 120b. In other words, the vertical elongate members 120a, 120b may have substantially the same structural configuration as the horizontal elongate members 110a, 110b. They may differ in, for example, length and the thickness of the material used to form the elongate member. They may also differ in the presence of tabs 111a-d. For example, in the depicted embodiment, the horizontal elongate member 110a is depicted as comprising tabs 111a-d, whereas the vertical elongate members 120a, 120b is shown to comprise slots (see Figures 3A and 3B). However, it is contemplated that the horizontal elongate members 110a, 110b may, alternatively or additionally, comprise slots and the vertical elongate members 120a, 120b may, alternatively or additionally, comprise tabs.

Turning to the intermediate frame 200, Figure 4 depicts a strip 210a which forms one edge of the aperture 230 defined by the intermediate frame 300. The strip 210a comprises a first flange 212 and a second flange 214, each connected to opposing edges of a bridging member 216. The first flange 212, second flange 214, and bridging member 216 form a substantially U-shaped cross-section of the strip 210a.

In the depicted embodiment, the second flange 214 comprises an angled portion 214’ that may assist a user when attaching the strip 210a to the support structure 100. More specifically, the angled portion 214’ is angled away from the first flange 212 so as to provide an increased opening of the U-shaped cross-section of the strip 210a for receiving the respective elongate member of the support structure 100.

The second flange 214 further comprises fastening means 215 in the form of screw holes 215. The fastening means 215 allows the second flange to be secured (e.g. by screws) to the elongate members when the intermediate frame 200 is secured to the support structure 100. Alternative fastening means are also contemplated.

The first flange 212 comprises beading 218 for receiving liquid plaster. The beading comprises a plurality of perforations through the first flange 212. This allows liquid plaster (or other liquid construction materials) to be applied to the first flange 212 and retained by the perforations while the liquid dries. The second flange 214 may optionally also comprise beading.

It will be appreciated that the intermediate frame 200 may instead be of unitary construction and thereby not comprise a plurality of strips 210a-d. In such embodiments, the aforementioned features, characteristics, and advantages apply equivalently to the edges of the intermediate frame 200. In such embodiments, it may be considered that the intermediate frame 200 comprises a single first flange, a single second flange, and/or a second bridging member (each extending around the entire perimeter of the intermediate frame 200).

Turning to Figures 5A-5C, the interaction between the support structure 100 (and specifically the elongate members) and the intermediate frame 200 (and specifically the strips) will be described. Figures 5A-5C depict the specific interaction between vertical elongate member 120a and strip 210d, however, it will be appreciated that equivalent interactions occur between each elongate member and the corresponding strip.

Figure 5A is a top view of vertical elongate member 120a of support structure 100 prior to receiving the intermediate frame 200. The vertical elongate member 120a comprises a first sidewall 122, a second sidewall 124, and a third sidewall 126 arranged into a U- shaped cross-section defining a space 127, in much the same way as described with respect to Figure 2. The vertical elongate members 120a further comprises a first elongate lip 128 and may further comprise a second elongate lip 129. Figure 5B shows the vertical elongate member 120a after the intermediate frame 200 has been inserted into the opening 130 and secured to the support structure 100. More specifically, the strip 21 Od of the intermediate frame 200 can be seen to be placed over the vertical elongate member 120a. The vertical elongate member 120a is received by the space 117 of the strip 21 Od. The width of the bridging member 216 (i.e. the spacing between the first flange 212 and the second flange 214) is sufficient to enclose the vertical elongate member 120a.

As can be seen in Figure 5B, when the vertical elongate member 120a is received by the strip 21 Od, the first flange 212 is arranged to define a channel 150 between the first flange 212 and the first sidewall 122 of the vertical elongate member 120a. The bridging member 126 is arranged to extend towards the second sidewall 124 of the vertical elongate member 120a, thereby extending through the opening 130 of the support structure 100. The second flange 214 is arranged to abut the second sidewall 124 of the vertical elongate member 120a.

The channel 150 is for receiving one or more sheets of wall material, as can be seen in Figure 5C. In particular, in Figure 5C, three sheets 310a-c of wall material have been inserted into the channel 150, parallel to the plane of the opening 130. The sheets 310a-c are held in place between the first sidewall 122 and the first flange 212, with the strip 21 Od being held in place by the second flange 214. It will be appreciated that, alternatively or additionally, the third sidewall 216 may be secured to the third sidewall 126 of the vertical elongate member 120a, such that the second flange 214 is not required. In either case, the intermediate frame 200 thereby holds the sheets 310a-c in place to allow the wall to be finished around the apparatus 1 .

It will be appreciated that the dimensions of the channel 150 determine the number and width of the sheets 310a-c. The strips 210a-d and the elongate members 110a, 110b, 120a, 120b may be manufactured so as to determine a particular shape and dimension of the channel 150 to receive the appropriate number and thickness of the sheets 310a-c of wall material.

It will be understood that in embodiments in which the vertical elongate member 120a comprises a second elongate lip 129, the strip 210d may be manufactured with a larger spacing between the first flange 212 and the second flange 214 such that a second channel (not shown) may be formed, in much the same manner, between the second flange 214, the second sidewall 124, and the second elongate lip 129. This allows the reception of one or more sheets of wall material on both sides of the wall into which the apparatus 1 is installed.

The arrangement of the sheets 130a-c of wall material in the channel 150 can further be seen in Figures 6 and 7, which depict the apparatus 1 installed in a wall 300 (shown in cutaway). The wall 300 comprises the sheets 310a-c of wall material and a plurality of studs 320. The wall 300 therefore constitutes a stud wall. The studs 320 may be secured to the elongate members 110a, 110b, 120a, 120b of the support structure 100 in any conventional way known in the art (for example, by screwing the studs onto the support structure 100). The wall 300 is disposed on a floor 400, onto which the apparatus 1 is secured (e.g. by way of brackets 140a-d). It will be noted that the lowermost horizontal elongate member 110b protrudes slightly above the floor 400. It is therefore advantageous for at least this horizontal elongate member 110b to be formed of thicker/stronger material so as to prevent damage caused by construction workers stepping onto the horizontal elongate member 110b during construction. In some embodiments, the apparatus 1 may not comprise the horizontal elongate member 110b or the lowermost strip 210c. Therefore the opening 130 and the aperture 230 would be defined by the three remaining elongate members 110a, 120a, 120b, the three remaining strips 210a, 210b, 210d, and the floor 400.

A method 500 of installation of the apparatus 1 into the wall 300 will now be described with reference to Figure 8.

The method 500 may comprise, in particular when the support structure 100 is not integrally formed as a unitary structure, arranging 502 the plurality of elongate members 110a, 110b, 210a, 210b to form the support structure 100 to define the opening 130. When the support structure 100 is integrally formed as a unitary structure, it will be appreciated that the support structure 100 does not need to be formed in this manner.

Arranging 502 the plurality of elongate members 110a, 110b, 210a, 210b to form the support structure 100 may comprise inserting a tab 111a-d of a horizontal elongate member 110a, 110b into a slot 121a, 121b of a vertical elongate member 120a, 120b and bending the tabs 111a-d in order to secure the horizontal elongate member 110a, 110b to the vertical elongate member 120a, 120b. This is described in more detail above with reference to Figures 3A and 3B.

The method 500 comprises securing 504 one or more of the plurality of elongate members 110a, 110b, 210a, 210b to the floor 400 and/or a ceiling of the building into which the apparatus 1 is to be installed. For example, the vertical elongate members 210a, 210b may be secured to the floor 400 and/or the ceiling. The securing may be by way of the brackets 140a-d. Alternatively, any known securing means may be used.

The method 500 may further comprise attaching 506 one or more wall studs 320 to the support structure 100 to define a wall 300 containing the support structure 100.

The method 500 further comprises positioning 508 the intermediate frame 200 in the opening 130 of the support structure 130. Positioning 508 the intermediate frame 200 in the opening 130 may comprise, in particular when the intermediate frame 200 is not integrally formed as a unitary structure, inserting one or more strips 210a-d into the opening 130.

The method 500 further comprises securing 510 the intermediate frame 200 to the support structure 100. Securing 510 the intermediate frame 200 to the support structure 100 may comprise securing each of the strips 210a-d to a respective edge of the opening 130, for example, by way of screw holes 215 on the second flange 214 of the strips 210a-d.

The method 500 further comprises positioning 512 one or more sheets 310a-c of wall material such that the one or more sheets 310a-c are received by the channel(s) 150 defined between the first flange 212 (and/or the second flange 214) and the corresponding elongate members 110a, 110b, 120a, 120b.

The method 500 may further comprise inserting 514 an access panel and/or an access panel frame into the aperture 230 of the intermediate frame 200. The method 500 may further comprise connecting 516 the access panel and/or the access panel frame to the intermediate frame 200, for example, by way of the connection mechanisms as described herein.

Claims

25 CLAIMS:

1. An apparatus for receiving an access panel and/or an access panel frame into a wall, the apparatus comprising: a support structure comprising a plurality of elongate members arranged to define a square or rectangular opening, each of the elongate members forming a respective edge of the opening; and an intermediate frame defining an aperture for receiving the access panel and/or the access panel frame, wherein the intermediate frame is shaped and dimensioned to match the internal dimensions of the opening of the support structure, the intermediate frame being secured to the support structure and positioned within the opening, wherein the intermediate frame comprises one or more flanges, each flange being parallel to a corresponding elongate member and arranged to define a channel between the flange and the corresponding elongate member for receiving one or more sheets of wall material.

2. The apparatus of claim 1, wherein the intermediate frame comprises a first flange, a second flange, and a bridging member connecting the first flange to the second flange, wherein: the first flange is arranged to define the channel between the first flange and a first sidewall of the corresponding elongate member; the bridging member is arranged to extend through the opening towards a second sidewall of the corresponding elongate member; and the second flange is arranged to abut the second sidewall of the corresponding elongate member.

3. The apparatus of claim 1 or claim 2, wherein one or more of the flanges of the intermediate frame comprise beading for receiving liquid plaster.

4. The apparatus of any of the preceding claims, further comprising a connection mechanism configured to, upon insertion of the access panel and/or the access panel frame into the aperture of the intermediate frame, connect the access panel and/or the access panel frame to the intermediate frame.

5. The apparatus of any of the preceding claims, wherein each of the elongate members comprises: a sidewall extending along the length of the elongate member and protruding in a direction parallel to a plane of the opening; and an elongate lip extending along the length of the elongate member and protruding in a direction perpendicular to the plane of the opening, wherein, for each elongate member, the sidewall, the elongate lip, and a corresponding flange define the channel for receiving the one or more sheets of wall material.

6. The apparatus of any of the preceding claims, wherein each elongate member comprises a U-shaped or box-shaped cross-section portion.

7. The apparatus of any of the preceding claims, wherein the plurality of elongate members comprises: one or more first elongate members arranged to provide horizontal edges of the opening when the apparatus is installed; and one or more second elongate members arranged to provide vertical edges of the opening when the apparatus is installed.

8. The apparatus of claim 7, wherein the first elongate members are manufactured from a first sheet material and the second elongate members are manufactured from a second sheet material, wherein the first sheet material is of greater thickness than the second sheet material.

9. The apparatus of claim 7 or claim 8, wherein the first elongate members are longer than the second elongate members.

10. The apparatus of any of claims 7 to 9, wherein each of the first elongate members comprises a tab at each end of the first elongate member, and each second elongate member comprises a slot, wherein each tab is inserted into a respective slot to join each first elongate member to a respective second elongate member.

11. The apparatus of claim 10, wherein each slot is positioned along the length of a second elongate member so as to define a dimension of the opening.

12. The apparatus of claim 10 or claim 11 , wherein the tabs are flexible so as to allow them to be bent, thereby securing the first elongate member to the second elongate member.

13. The apparatus of any of claims 1 to 9, wherein the plurality of elongate members are integrally formed with one another to form the support structure.

14. The apparatus of any of the preceding claims, further comprising an access panel and/or an access panel frame, wherein the intermediate frame is shaped and dimensioned such that the aperture matches the shape and dimensions of the access panel and/or the access panel frame.

15. A kit of parts comprising: a plurality of elongate members configured to be arranged to form a support structure that defines a square or rectangular opening such that each of the elongate members forms a respective edge of the opening; and one or more strips securable to the support structure within the opening to form an intermediate frame that defines an aperture for receiving an access panel and/or an access panel frame, wherein the one or more strips are dimensioned such that, when the one or more strips are secured to the support structure, the intermediate frame is shaped and dimensioned to match the internal dimensions of the opening of the support structure, wherein the one or more strips comprise one or more flanges such that, when the one or more strips are secured to the opening, each flange is parallel to a corresponding elongate member and arranged to define a channel between the flange and the corresponding elongate member for receiving one or more sheets of wall material.

16. The kit of parts of claim 15, wherein the one or more strips are pre-assembled to form an intermediate frame being securable to the support structure within the opening.

17. The kit of parts of claim 15 or claim 16, further comprising an access panel and/or an access panel frame, wherein the one or more strips are shaped and 28 dimensioned such that, when assembled into an intermediate frame, the aperture matches the shape and dimensions of the access panel and/or the access panel frame.

18. A method of installation of the apparatus according to any one of claims 1-14 for receiving an access panel and/or an access panel frame into a wall, the method comprising: securing one or more of the elongate members to a floor and/or a ceiling of a building into which the apparatus is to be installed; positioning the intermediate frame in the opening; securing the intermediate frame to the support structure; and positioning one or more sheets of wall material such that the one or more sheets are received by the channels defined between one or more flanges and corresponding elongate members.

19. The method of claim 18, further comprising, prior to securing one or more of the elongate members, arranging the plurality of elongate members to form the support structure such that each of the elongate members forms a respective edge of the square or rectangular opening in the support structure.

20. The method of claim 19, wherein arranging the plurality of elongate members comprises: inserting a tab of a first elongate member into a slot of a second elongate member; and bending the tab in order to secure the first elongate member to the second elongate member.

21. The method of any of claims 18 to 20, further comprising, prior to positioning the one or more sheets of wall material, attaching one or more wall studs to the support structure to define a stud wall structure including the support structure.

22. The method of any of claims 18 to 21 , wherein positioning the intermediate frame in the opening comprises inserting one or more strips into the opening, and wherein securing the intermediate frame to the support structure comprises securing each of the strips to a respective elongate member. 29

23. The method of any of claims 18 to 22, further comprising: inserting the access panel and/or the access panel frame into the aperture of the intermediate frame; and connecting the access panel and/or the access panel frame to the intermediate frame.