GB2475259A

GB2475259A - Template for shielding an electrical back box from unset plaster

Info

Publication number: GB2475259A
Application number: GB0919713A
Authority: GB
Inventors: Barry Jenkinson
Original assignee: CABB IP Ltd
Current assignee: CABB IP Ltd
Priority date: 2009-11-11
Filing date: 2009-11-11
Publication date: 2011-05-18
Anticipated expiration: 2029-11-11
Also published as: GB2475259B; GB0919713D0

Abstract

The template comprises a former and a stabiliser. The former is inserted into the back box and has at least one flexible side wall to allow the former to be sprung into place within the box. The stabiliser fits within the former and reinforces the or each side wall of the former. The template may be made of card, plastic or metal and have a waterproof exterior surface. The former may include legs 14 to extend to the corners of the box and flaps 15 to cover mounting flanges of the box. The flaps may have screw holes 18 to fix the template to box. The side walls may include a score 17 along the centre for folding and a double thickness portion 16. The stabiliser may include at least one finger hole or a flap to provide a grip means.

Description

PLASTERING TEMPLATE

Field of the Invention

The present invention relates to a device providing a template in plastering operations. It is particularly concerned with a template for assisting plastering in the vicinity of electrical fittings.

Background to the Invention

In constructing a building, electrical boxes, hereinafter called back boxes, are attached to walls at predetermined locations and, usually, the wiring fitted, prior to the walls being plastered. Then, when plastering, the plasterer has to cope with the back boxes, having the problems both of keeping the plaster level in the vicinity thereof and, as far as possible, keeping it out of the back boxes. This aspect of the plasterer's operation can add significantly to the time taken to complete, for example, a room.

The present invention provides a template enabling a plasterer to bring the plaster to the sides of a back box quickly and evenly and to avoid plaster entering the back box.

Temporary back box covers are described in US Patent Specifications 5,562,222 (Jordan), 6,538,202 (Shaffer) and 7,442,874 (Compagnone).

US Patent Specification 5,562,222 describes a moulded cover plate, formed as a continuous, unbroken unit preferably of a plastics material. It is formed with ridges and grips by which it can be fitted to a back box and readily removed.

US Patent Specification 6,538,202 likewise describes a cover moulded from a plastics material and constructed with depth whereby it can fit into a back box and a ridge enabling removal therefrom. It has flanges attachment flanges extending significantly laterally from the back box.

US Patent Specification 7,442,874 describes a cover comprising a faceplate, anchor boxs and a removal tongue and moulded from a plastics material.

These covers may be relatively expensive and do not perform the function of providing a stop wall to which the plaster can be moulded and smoothed.

Summary of the Present Invention

According to the present invention there is provided a template for plastering in the vicinity of a back box, the template comprising a former and a stabiliser, the former comprising a former member constructed to sit snugly inside a back member, having at least one side wall flexible to allow the former member to be sprung into place within a back box, and the stabiliser constructed to fit within the former member to reinforce the sidewalls thereof.

Although the former member may be a strip of material with preformed corner arrangements it is preferably formed as a continuous frame, with the corners preformed. The arrangement is thus preferably such that the former member can be sprung into place in a back box by pinching in the said at least one side wall, inserting the former member into the back box and allowing or manoeuvring the side walls to revert to a natural configuration contiguous with the walls of the back box, then emplacing the stabiliser within the former member whereby the former member side walls are maintained against the back box side walls.

According to a feature of the invention the former may have a reinforcement on the former member walls and exterior thereto and which in use will sit upon the back box.

It will be usual for there already to be wires in the back box when plastering is to occur. However these normally curve around in the interior of the back box and do not lie in the corners thereof. Accordingly the former member may incorporate leg members formed to extend into the corners of a back member, thus reducing the scope for interference between the former member side walls and such wiring. For the event that an earth terminal is incorporated in one corner of a back box, as is often the case, the appropriate leg member may be shortened accordingly.

The former member will usually also need to avoid conflict with the back box faceplate mount screw holes normally formed in flanges protruding inwards from two opposite sides of the back box. Preferably however the former member is formed with flap members arranged for sitting on the mount flanges, perhaps scored for possible screw attachment of the template thereto. Such flap members afford the added advantage of stiffening the former member side walls. This arrangement may be incorporated in all four walls of square templates given that square back boxes often have faceplate mounting flanges on all four walls. These flap members may indeed be arranged to provide siting, even anchorage, of the former within the back box and may be used in place of legs entirely.

The former member, at least, is preferably formed of a material with a waterproof, for example waxed or plasticised, exterior surface. This can reduce the possibility of the plaster adhering thereto. Also it can assist in enabling the template to be reusable.

In fact both the former and the stabiliser may be made of similar material. Indeed the template may be supplied with the former and the stabiliser conjoined, perhaps detachably. The template may, moreover be supplied as a flat pack, which is to say that the corners can be previously scored for bending. A centre portion of the said at least one of the side walls may also be scored for folding. Preferably it is two opposing such side walls which are pre-prepared for flexing; in the case of a double or triple socket back box this may well be the longer two side walls.

Advantageously the stabiliser incorporates grip means, for example at least one hole, facilitating its emplacement in and, more particularly, its removal from the former.

Whilst the hole, or perhaps two holes, may be circular, they may be formed from scoring the material, in which case flaps may be formed which can complete the closure effected by the stabiliser and minimise the possibility of ingress of plaster etc into the back box during plastering and with which the stabiliser can be extracted after use.

Typically in the case of a disposable template the former and the stabiliser may be manufactured from card, properly called board. 12 sheet or 750 micron board may be suitable, particularly for the single socket back box. It is not normally necessary to use board over 1500 microns, and 1000 micron thick board, plasticised on both sides, appears to be particularly suitable in terms of rigidity and cost. A reusable template may be formed of a plastics material or metal. The former member may be constructed to protrude 15 to 35 mm beyond the back box edge, and to be susceptible of trimming of required.

The former member may be arranged for being readily cut so that the outer edge provides a former to which the plaster is skimmed. In the case of working to a wallboard a standard pencil laid on the wallboard can mark a line on the former wall indicating a level approximately 3mm proud of the wall board, this being the usual thickness of plaster skim in that circumstance.

Notwithstanding the possibilities for cutting the template members, it will be appreciated that the template can readily be constructed for repeated use. A kit for example may include means for applying a polyvinyl acetate (pva) coating to cut edges to minimize penetration into the template material by water from the plaster.

It will usually be the case that the template is to be removed from the back box. This will preferably be effected when the plaster is substantially dry. It is an advantage of templates in accordance with the invention that removal can be effected leaving plaster intact and clean edged.

Sometimes an insulated plasterboard having a thickness of 45mm is employed, so that the back box lies somewhat deeper therebehind than is normally the case with thinner or no plasterboard. As it will generally not be preferred that the former member is so sized always to cater for this there may be provided an extension former comprising an outer box having sides of a similar length to those of the former member, which can abut the edges of the former member and sit thereupon, and inner walls attached inside the outer box and arranged to sit within the former member. An extension stabiliser may be required, slightly smaller that the stabiliser above described.

Templates in accordance with the invention can be particularly beneficial when plastering in the region of a plurality of back boxes separated by distances of the order of 1 to 5 cm. A plasterer normally has tools for plastering strips in such locations. Templates in accordance with the invention render plastering in such circumstances considerably easier than before.

A particular advantage of the present invention is that the template can be manufactured for sale at a price significantly lower than the cost of a plasterer's time taken up with ensuring a smooth finish in the region of a back box.

Description of the Drawings

Embodiments of the present invention will now be described by way of example with reference to the accompanying drawings, of which: Figure 1 is an isometric view of a double socket back box; Figure 2 is an isometric view of a first former member; Figure 3 is an isometric view of a first stabiliser viewed from above; Figure 4 demonstrates a first former member being fitted in a back box; Figure 5 is a further view of a first former member; Figure 6 is shows a first stabiliser viewed from below; Figures 7 and 8 are views of a second former member; Figure 9 illustrates a template fitted in a double socket back box; Figure 10 is an isometric view of a second, single socket back box former member; Figure 11 is an isometric view of a second stabiliser; and Figure 12 is an isometric view of a second template installed in a single socket back box.

Description of Preferred Embodiments

Referring to figures 1 to 6 there is shown a first embodiment of a plastering template for use with a standard double electrical socket back box, the back box itself being illustrated in figure 1. This is a box formed, usually, of a galvanised metal, having wire access holes 10, fixing holes 11 and faceplate anchoring screw holes in inwardly projecting flanges 12.

A former member for use with the back box shown in figure 1 is shown in figures 2 and 5. It comprises a frame 13 having legs 14 and, projecting inwards from the shorter walls, seating flaps 15. The frame 13 has a double thickness portion 16.

Folds 17 are formed at the middle of the longer walls. Fixing holes 18 are formed in the flaps 15.

A stabiliser is shown in figures 3 and 6. It comprises a rectangular plate member 30 having at each side folding flanges 31, 31 a. Two grip flaps 32 are formed by scoring and being pressed out of the plate member 30. The stabiliser is made with dimensions such that in place it will urge the walls of the former member against those of the back box. At the ends of the stabiliser the flanges 31a are incomplete, allowing them to straddle the seating flaps 15.

The former member is constructed to fit snugly in the back box, that is so as to touch all four side walls thereof at the same time, with the lower edge of the double thickness portion 16 resting upon the outer edge of the back box. Moreover the flaps are constructed to bed on the back box flanges 12.

To fit the template into a back box the folds 17 are squeezed inwards to draw the sides thereof inwards and the former member is offered to the back box. A combination of releasing the pressure on the folds 17 and pushing the former member into the back box results in the former member bedding on the back box by either or all of the legs 14, the double thickness portion 16 and the seating flaps 15 grounding. A stabiliser is then inserted into the former member with the flaps 31, 31 a first.

The arrangement is then as depicted in figure 9.

In an alternative stabiliser the flaps 31a are complete and not bifurcated and the depth of the flaps 31, 31a is such that flaps 31a bed on the flaps 15, 74, 93 and ensure that the stabiliser is located adjacent the back box edge.

The embodiment of the former member shown in figures 7 and 8 comprises side walls 70 having a central fold 71. In place of the corner legs 14 with their squared feet, this embodiment has legs 72 terminating in pointed feet. At each end wall an edge 73 denotes a fold supporting a seating flap 74 as per seating flaps 15.

This embodiment has no reinforcing double thickness portion 16 and uses a stabiliser as shown in figures 3 and 6.

The precise outside dimensions of a former member frame 13 between corners is 13cm long by 7cm broad and 61mm deep. The legs 14 are 25mm long and extend 22mm from the corners.

It will be appreciated that either of these embodiments may lack a double thickness portion 16 and indeed may lack legs 14, 72, relying on flaps 15 for seating.

The embodiment shown in figures 10 to 12 is for use with a single socket electrical back box 90.

It comprises a frame 91 having corner legs 92 and, projecting inwards from opposite two walls, seating flaps 93. The frame 91 has a double thickness portion 94. Folds 95 are formed at the middle of the other two opposing walls. Fixing holes, not shown, are formed in the flaps 93.

A stabiliser is shown in figure 10. It comprises a square plate member 96 having at each side folding flanges 97. A grip flap 98 is formed by being pressed out of the plate member 96. The stabiliser is made with dimensions such that in place it will urge the walls of the former member against those of the back box.

The former member is constructed to fit snugly in the back box, that is so as to touch all four side walls thereof at the same time, with the lower edge of the double thickness portion 94 resting upon the outer edge of the back box. Moreover the flaps are constructed to bed on the back box faceplate anchoring flanges.

To fit the template into a back box the folds 95 are squeezed inwards to draw the sides thereof inwards and the former member is offered to the back box. A combination of releasing the pressure on the folds 95 and pushing the former member into the back box results in the former member bedding on the back box by either or both of the legs 92 and the seating flaps 93 grounding. A stabiliser is then inserted into the former member using the flap 98.

As with the double socket back box template embodiment the single socket embodiment may lack a double thickness or legs or both.

The former and the stabiliser are manufactured from 1000 micron card, coated with polyvinyl acetate (pva).

The former member is thus arranged for being readily cut so that the outer edge provides a former to which the plaster is skimmed. In the case of working to a wallboard a standard pencil laid on the wallboard can mark a line on the former wall indicating a level approximately 3mm proud of the wall board, this being the usual thickness of plaster skim in that circumstance.

Notwithstanding the possibilities for cutting the template members, it will be appreciated that the template can readily be constructed for repeated use. A template kit accordingly includes means for applying a polyvinyl acetate (pva) coating to cut edges to minimize penetration into the template material by water from the plaster.

Removed of the template from the back box is effected when the plaster is substantially dry by first withdrawing the stabiliser by the depressing flaps 32, 98 and inserting a finger into the surrounding hole, then squeezing the folds to bring the former member walls away from the back box. This will leave the plaster intact and clean edged.

For the case when an insulated plasterboard having a thickness of 45mm is employed, so that the back box lies somewhat deeper therebehind than is normally the case with thinner or no plasterboard, there is provided an extension former comprising an outer box having sides of a similar length to those of the former member, which can abut the edges of the former member and sit thereupon, and inner walls attached inside the outer box and arranged to sit within the former member. An extension stabiliser is likewise fabricated, slightly smaller that the stabiliser above described.

Claims

CLAIMS1. A template for plastering in the vicinity of a back box, the template comprising a former and a stabiliser, the former comprising a former member constructed to sit snugly inside a back box, having at least one side wall flexible to allow the former member to be sprung into place within a back box, and the stabiliser constructed to fit within the former member to reinforce the sidewalls thereof.
2. A template as claimed in claim 1 and wherein the former member is a strip of material with preformed corner arrangements.
3. A template as claimed in claim 1 and wherein the former comprises a continuous frame, with the corners preformed.
4. A template as claimed in any one of clams 1 to 3 and wherein the former has a reinforcement on the former member walls and exterior thereto and which in use will sit upon the back box.
5. A template as claimed in any one of the preceding claims and wherein the former member incorporates leg members formed to extend into the corners of a back box.
6. A template as claimed in any one of the preceding claims and wherein the former is formed with flap members arranged for sitting on the mount flanges.
7. A template as claimed in claim 6 and wherein the flap members are scored for possible screw attachment to the back box
8. A template as claimed in any one of the preceding claims and formed of a material with a waterproof exterior surface.
9. A template as claimed in any one of the preceding claims and wherein a centre portion of at least one of the former member side walls is scored for folding.
10. A template as claimed in any one of the preceding claims and wherein the stabiliser incorporates grip means.
11. A template as claimed in claim 10 and wherein the stabiliser grip means comprises at least one finger hole.
12. A template as claimed in claim 10 and wherein the grip means comprise flaps.
13. A template as claimed in any one of the preceding claims and manufactured from 1000 micron card.
14. A template as claimed in any one of claims ito 12 and formed of a plastics or metal.
15. A template as claimed in any one of the preceding claims and arranged for being readily cut so that the outer edge provides a former to which the plaster is skimmed.
16. A template as claimed in any one of the preceding claims and comprising an extension former comprising an outer box having sides of a similar length to those of the former member, which can abut the edges of the former member and sit thereupon, and inner walls attached inside the outer box and arranged to sit within the former member and an extension stabiliser.