GB2480481A

GB2480481A - Hole edge protector

Info

Publication number: GB2480481A
Application number: GB1008427A
Authority: GB
Inventors: John David Flynn
Original assignee: Individual
Current assignee: Individual
Priority date: 2010-05-20
Filing date: 2010-05-20
Publication date: 2011-11-23
Also published as: GB2480540A; GB201108246D0; GB201008427D0

Abstract

A hole protector (10) or liner protects the bore (64) and edge (66) of a through hole (42) in a frangible sheet material (32), to strengthen and reinforce the edge so that a recessed ceiling light can be installed in the hole and retained within the hole protector lining. The hole protector (10) comprises: an annular portion (26) for protecting the bore (64) of the through hole (42); a flange portion (14) for protecting the edge (66) of the through hole (42); and a plastically deformable retaining means (28) extending from an opposite end of the annular portion (26) to the flange portion (14), which retaining means (28) is outwardly bendable to engage an opposite surface (60) of the sheet material (32) to the flange portion (14) and retain the hole protector (10) in situ. The retaining means may be tabs formed by slits cut in an end of the annular portion.

Description

HOLE PROTECTOR

Description:

This invention relates to hole protectors, and in particular, but without limitation to hole protectors suitable for use in plasterboard structures.

Building interiors nowadays often comprise walls and ceilings that are manufactured of plasterboard sheets screwed or nailed to wooden battens. Such a configuration creates a plenum space behind the plasterboard facade which can be used to conceal pipes, wiring etc. Furthermore, the plasterboard provides an aesthetically pleasing, flat surface which is relatively easy to decorate and finish.

Because so-called "dry-lined" walls comprise a concealed space, it has become customary for users to make use of this space to house items that would otherwise be unsightly. For example, switch back boxes, light fittings and even television sets can be mounted in a through aperture in the plasterboard so as to lie flush with the plasterboard's surface.

One area where this practice is prevalent is in ceiling light fittings which are commonly of the recessed, halogen type. Such light fittings are very well-known and comprise a tubular body portion for receiving a lamp and through which power wires pass. A flange is normally also provided that abuts the plasterboard's surface to enable the light fitting to sit flush with the ceiling's surface and spring-loaded clips are normally also provided that engage the rear surface of the plasterboard and prevent the light fitting from falling out of the hole in which it sits.

A very well-known problem with these types of light fittings is that they tend to cause damage to the edges of the plasterboard during installation and removal of the light fitting. The damage caused is often irreversible, meaning that unless the damage can be concealed behind the light fitting's flange, an unsightly mess can be left, which can only be remedied by re-plastering the ceiling. As such, it is commonplace for an entire new ceiling to be required, or at least extensive repairs to be budgeted for, when fitting new, or replacing recessed ceiling light fittings. It is an object of this invention to provide a solution to one or more of the above problems.

According to a first aspect of the invention, there is provided A hole protector comprising an annular portion having first and second spaced-apart engagement means, wherein the first engagement means extends, and the second engagement means is deformable so as to extend, outwardly beyond an outer periphery of the annular portion.

Preferably, the first and second engagement means are located at, or towards opposite ends of the annular portion. The annular portion and one, or both, of the first and second engagement means may be integrally formed.

The primary function of the annular portion is preferably to protect the bore of the through hole. Accordingly, it is preferred that the external dimensions of the annular portion substantially correspond to the internal dimensions of the through hole to be protected. A snug, interference fit between the annular portion and the through hole's bore is preferred, although not so snug as to exert undue pressure on the surrounding structure, which may cause it to fragment. The axial length / depth of the annular portion is preferably substantially equal to the thickness of the sheet material from which the wall/ceiling is constructed. The length/depth of the annular portion is preferably adjustable.

The primary function of the first engagement means is preferably to provide an abutment with the wall/ceiling in which the hole is present to prevent the protector from passing therethrough beyond a desired extent. Secondary functions of the first engagement means may be to conceal an unsightly edge of the through hole and/or to protect an edge of the through hole.

The first engagement means may comprise an outwardly projecting flange, one or more tabs and/or a tapered/flared portion. In all cases, the first engagement means is preferably adapted to engage, or wrap around, the edge of the through hole and to engage a surface of the wall/ceiling in which the through hole is located.

The second engagement means is preferably plastically deformable, i.e. so that it can be bent/twisted and substantially retain a deformed shape/configuration. The second engagement means preferably comprises one or more tabs or fingers that can be bent plastically outwardly so as to engage a surface of the wall/ceiling. The tabs or fingers, where provided, may be defined by substantially longitudinal slits in the annular portion, which slits intersect an end thereof.

The hole protector is preferably manufactured of metal. Mild steel and aluminium are preferred materials as they can be relatively easily press-formed and are plastically deformable.

Because the hole protector is likely to used in conjunction with hot electrical equipment (e.g. recessed light fittings), and possibly in humid/condensing environments (e.g. kitchens and bathrooms), it is preferred that a surface coating be provided to improve the hole protector's efficacy, functionality, longevity, safety and/or appearance. Suitable surface coating may comprise paint, a plastics coating (e.g. a dip coating), an intumescent and/or thermally resistive coating, or an electrically insulative coating.

A second aspect of the invention provides a hole protector for protecting the bore and edge of a through hole in a frangible sheet material, the hole protector comprising: an annular portion for protecting the bore of the through hole; a flange portion for protecting the edge of the through hole; and a plastically deformable retaining means extending from an opposite end of the annular portion to the flange portion, which retaining means is/are outwardly bendable to engage an opposite surface of the sheet material to the flange portion and retain the hole protector in situ.

A third aspect of the invention provides a method of installing an electrical fitting in a frangible wall or ceiling comprising the steps of: forming a through hole in the wall or ceiling; inserting a hole protector as described above in the through hole; abutting the first engagement means against a first surface of the wall or ceiling; and deforming the second engagement means so as to engage a second surface, opposite the first surface, of the wall or ceiling.

The hole protector may be used to protect the bore and/or edges of a through hole in a frangible ceiling or wall, for example: a dry lined ceiling or wall; a wall or a ceiling manufactured of lath and plaster; fibreboard; or acoustic tiles that ceilings in commercial premises are often manufactured from. For the sake of appearance, a skim coat of plaster may be applied over a visible surface of the wall/ceiling, in which case it is preferable to install the hole protector(s) prior to applying the skim coat, such that at least part, but preferably all, of the flange portion/first engagement means of the hole protector is concealed behind the plaster skim coat.

A preferred embodiment of the invention shall now be described, by way of an example only, with reference to the accompanying drawings in which: Figure 1 is a perspective view of a hole protector according to the invention; and Figure 2 is a partial cross-section through a dry lined ceiling comprising a through hole for receiving a recessed light fitting in which the hole protector of Figure 1 has been installed.

In Figure 1, a hole protector 10 comprises a cylindrical tube body portion 12 and a circumferential flange 14 extending radially outwardly from a first end 16 (as shown in Figure 1) thereof.

A second end 18 of the tubular body portion 12 comprises a number of longitudinal slits 20 that intersect, and that extend downwardly from, the upper edge 22 of the body portion 12 to points 24 lying on a circumferential line around the body portion 12. A continuous, annular portion 26 of the body 12 is located between the flange 14 and the lower ends 24 of the slits 20. Adjacent pairs of slits 20 together define finger portions 28 therebetween, which finger portions 28 are employed, in use, to retain the hole protector 10 in position.

In Figure 2, a dry lined ceiling 30 comprises a sheet of plasterboard 32 that has been screwed at intervals to battens 34. The battens 34 serve to create a space 36 between the plasterboard sheet 32 and a backing structure 38. The space 36 is useful for concealing wires 40 and other unsightly elements, e.g. an uneven backing structure 38.

A through hole 42 has been cut in the plasterboard sheet 32 for receiving a recessed light fitting 44 of conventional design. The recessed light fitting 44 comprises a tubular body 46 for receiving a light bulb 48, which is retained by clamping its peripheral edge between a lip 50 and a circlip 52. The tubular body 46 is retained in the through hole 42 by the action of a pair of spring-loaded clips 54 that clamp the plasterboard 32 against a flange portion 56 that abuts the visible side of the ceiling 30. In normal circumstances, this is all that would be provided.

However, the plasterboard 32 is frangible and can be made even more so by exposure to the heat of the bulb 48. Moreover, the constant pressure of the spring-loaded clips 54 exerting a compressive force on the plasterboard 32, can cause the edges 58 of the hole 42 to break-up. This can result in hole-enlargement to such an extent that it is no longer concealed behind the light fitting's flange 56, or detachment of the light fitting 44 from the ceiling 30.

In Figure 2, however, it will be noted that a hole protector 10 has been installed prior to installation of the light fitting 44. In this case, a through hole 42 is prepared in the ceiling in the usual way and the body 12 of the hole protector 10 inserted therethrough until the flange 14 abuts the plasterboard's surface 60. The installer then bends the finger portions 28 of the hole protector outwardly until they fan out over the back surface 62 of the plasterboard 32. The finger portions 28 thereby prevent the hole protector 10 from falling out of the through hole 42.

It will be noted that the finger portions 28 are relatively long compared to the thickness of the plasterboard 32, which means that they can be bent outwardly at different positions along their length. This is particularly useful where the plasterboard is of increased thickness, as might be the case where the ceiling has been double-boarded, or where its thickness is non-uniform. Thus, a single type of hole protector 10 can be customised in situ, meaning that a single type of hole protector 10 can be used in a variety of situations.

It will be apparent that the hole protector 10 of the invention, once installed, becomes a (semi) permanently installed, and/or integral part of the wall/ceiling, and does not form part of the light fitting. It will also be readily apparent that the hole protector 10 protects the hole in numerous ways. Firstly, the annular portion 26 thereof lies against, and protects the bore 64 of the through hole 42. Secondly, the flange portion 14 wraps around, protects and conceals the front peripheral edge 66 of the through hole 42. Thirdly, the finger portions 28 protect, wrap around, and conceal the back peripheral edge 68 of the through hole 42 and, in addition, provide a protective surface for the light fitting's spring-loaded clips 54 to bear against.

Once installed, a plasterer can then apply a skim coat of plaster 70 over the visible surface 60 of the plasterboard 32 and the flange 14 of the hole protector 10. Once the skim coat 70 has set, a light fitting can be installed in the protected hole as described above.

In the illustrated embodiment, the flange 14 is integrally formed with the body 12, which can be achieved by press-forming the hole protector 10 from a single disc of mild steel or aluminium, or by forming the flange 14 by swaging the end of a tube. Alternatively, the flange 14 and body 12 can be separate pieces that are made integral with one another by a joining process, such as welding or gluing. The hole protector 10 is provided with a thermally and electrically insulative surface coating to reduce the risk of electric shocks and to reduce the amount of heat that is transferred from the light bulb to the plasterboard.

The invention is not restricted to the details of the foregoing embodiment. For example, different materials/methods of manufacture and use may be employed. In addition, the external shape of the body portion 12 ideally substantially corresponds to the shape of a hole 42 to be protected. In the illustrated embodiment, a cylindrical body is used to protect a circular through hole. However, the hole protector could be used in different situations, such as to protect a hole in a wall for receiving a light switch or power socket, in which case the body would need to have a square-or rectangular-shaped cross-section.

Claims

Claims: 1. A hole protector comprising an annular portion having first and second spaced-apart engagement means, wherein the first engagement means extends, and the second engagement means is deformable so as to extend, outwardly beyond an outer periphery of the annular portion.
2. A hole protector as claimed in claim 1, wherein the first and second engagement means are located at, or towards opposite ends of the annular portion.
3. A hole protector as claimed in claim 1 or claim 2, wherein the annular portion and one, or both, of the first and second engagement means are integrally formed.
4. A hole protector as claimed in any of claims 1, 2 or 3, wherein the first engagement means comprises any one or more of the group comprising: an outwardly projecting flange; a tab; a tapered portion; and a flared portion.
5. A hole protector as claimed in any of claims 1 to 4, wherein the second engagement means is plastically deformable.
6. A hole protector as claimed in claim 5, wherein the second engagement means comprises one or more tabs or fingers that can be bent plastically outwardly.
7. A hole protector as claimed in claim 6, wherein the tabs or fingers are defined by substantially longitudinal slits in, and which intersect an end of, the annular portion.
8. A metal hole protector as claimed in any preceding claim.
9. A hole protector as claimed in any preceding claim, further comprising a surface coating.
10. A hole protector as claimed in claim 9, wherein the surface coating comprises any one or more of the group comprising: paint; a plastics coating; an intumescent coating; a thermally resistive coating; and an electrically insulative coating.
11. A hole protector for protecting the bore and edge of a through hole in a frangible sheet material, the hole protector comprising: an annular portion for protecting the bore of the through hole; a flange portion for protecting the edge of the through hole; and a plastically deformable retaining means extending from an opposite end of the annular portion to the flange portion, which retaining means is outwardly bendable to engage an opposite surface of the sheet material to the flange portion and retain the hole protector in situ.
12. A dry-lined ceiling or wall comprising a through hole and a hole protector as claimed in any preceding claim located in the through hole.
13. A dry lined ceiling or wall as claimed in claim 12, further comprising a skim coat of plaster located over a visible surface thereof, the skim coat of plaster additionally overlying at least part of the flange portion of the hole protector.
14. A method of installing an electrical fitting in a dry lined wall or ceiling comprising the steps of: forming a through hole in the wall or ceiling; inserting a hole protector according to any of claims 1 to 11 in the through hole; abutting the first engagement means against a first surface of the wall or ceiling; and deforming the second engagement means so as to engage a second surface, opposite the first surface, of the wall or ceiling.
15. A method as claimed in claim 14, further comprising the step of applying a skim coat of plaster over the first surface and over at least a portion of the first engagement means.