GB2480540A

GB2480540A - Hole protector

Info

Publication number: GB2480540A
Application number: GB1108246A
Authority: GB
Inventors: John David Flynn
Original assignee: SPOTBEAD
Current assignee: SPOTBEAD
Priority date: 2010-05-20
Filing date: 2011-05-17
Publication date: 2011-11-23
Also published as: GB201108246D0; GB2480481A; GB201008427D0

Abstract

A hole protector (10) for protecting the bore (64) and edge (66) of a through hole (42) in a frangible sheet material (32) comprises: a root portion (26, 82) for protecting the bore (64) of the through hole (42); a first flange portion (14,84) extending from a first edge of the root portion(66) of the through hole (42); and a second flange portion extending from the opposite edge, the second flange having transverse slits forming a series of tabs or fingers. The hole protector may be formed as or deformable into an annulus. A method of protecting edges of a hole using the hole protector is also disclosed. Alternatively a hole protector comprises an annular root portion having a first flange portion and a plastically deformable retaining means (28) extending from an opposite end of the annular root portion (26) to the first flange portion (14, 84), which retaining means (28) is outwardly bendable to engage an opposite surface (60) of the sheet material (32) to the first flange portion (14, 84) and retain the hole protector (10) in situ.

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 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 elongate root portion formed as or deformable into, an annulus, a first flange portion projecting outwardly from one longitudinal edge of the root portion and a deformable second flange portion projecting from the opposite edge of the root portion, wherein the second flange portion comprises a first plurality of incisions extending transversely from the longitudinal edge of the root portion and intersecting with an edge of the second flange portion, the first plurality of incisions defining a first plurality of tabs or fingers.

The hole protector may be supplied to the user in a condition in which the elongate root portion and the deformable second flange portion lie in a flat plane, in which case the user can first bend the protector into an annulus, whose diameter can be matched to that of the light fitting and/or hole, and then after installation bend the second flange portion outwards to form a retaining flange. In other embodiments the elongate root portion is pre-formed in an annular shape.

The primary function of the elongate root portion is to protect the bore of the through hole. Accordingly, it is preferred that the external dimensions of the root portion substantially correspond to the shape of the through hole to be protected. A snug, interference fit between the root 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 root portion is preferably S substantially equal to the thickness of the sheet material from which the wall/ceiling is constructed. The Length/depth of the root portion is preferably adjustable.

The first plurality of tabs or fingers are preferably plastically deformable, i.e. so that they can be bent/twisted and substantially retain a deformed shape/configuration. The first plurality of tabs or fingers can be bent plastically so as to engage a surface of the wall/ceiling.

According to an embodiment of the invention, the annulus is circular and the first flange portion extends radially away from a central axis.

According to an embodiment of the invention, the elongate root portion is planar.

According to a second aspect of the invention, there is provided a hole protector comprising a planar elongate root portion deformable into an annulus; a first flange portion projecting outwardly from one longitudinal edge of the root portion and a deformable second flange portion projecting from the opposite edge of the root portion, wherein the second flange portion comprises a first plurality of incisions extending transversely from the longitudinal edge of the root portion and intersecting with an edge of the second flange portion, the first plurality of incisions defining a first plurality oftabsorfingers.

According to another embodiment of the invention the first flange portion comprises a second plurality of incisions extending transversely from the longitudinal edge of the root portion and intersecting with an edge of the first flange portion, the S second plurality of incisions defining a second plurality of tabs or fingers.

The first flange portion 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 primary function of the first flange portion 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 flange portion may be to conceal an unsightly edge of the through hole and/or to protect an edge of the through hole.

According to a further embodiment of the invention, the second plurality of tabs or fingers are able to be plastically bent.

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.

The hole protector comprising a planar root portion is preferably made of sheet metal.

S

A third 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: a root 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 root 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.

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 fourth aspect of the present invention provides a method of protecting the bore and edge of a through hole in a sheet material comprising the steps of forming a hole protector to fit a shape of the through hole, the hole protector comprising: a planar elongate root portion deformable into an annulus, a first flange portion projecting outwardly from one longitudinal edge of the root portion and a deformable second flange portion projecting from the opposite edge of the root portion, wherein the second flange portion comprises a first plurality of incisions extending transversely from the longitudinal edge of the root portion and intersecting with an edge of the second flange portion, the first plurality of incisions defining a first plurality of tabs or fingers; inserting the hole protector into the through hole; abutting the first flange portion against a first surface of the sheet material; deforming the first plurality of tabs or fingers so as to engage a second surface of the sheet material.

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 first flange portion of the hole protector is concealed behind the plaster skim coat.

The term "annular" is to be understood herein to refer not only to shapes which are circular, but to any shape including, but not limited to, a square, rectangle, oval. In forming the hole protector into a shape, the ends of the elongate root portion may overlap.

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 an embodiment of the invention where a root portion is circularly annular; 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.

Figure 3 shows a plan view of another embodiment of the invention formed of sheet material.

Figure 4 shows a cross section of the hole protector shown in Figure 3.

Figure 5 shows the hole protector of Figure 3 after bending into a circular shape.

Figure 1 shows a hole protector 10 where a root portion is formed as a circular annulus portion 26. The hole protector 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 incisions 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. The continuous, annular portion 26 of the body 12 is located between the flange 14 and the lower ends 24 of the incisions 20. Adjacent pairs of incisions 20 together define finger portions 28 therebetween, which finger portions 2 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 10 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 of Figure 1, 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 in Figures 1 and 2, 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.

Figure 3 shows a hole protector 80 supplied to the user in a condition in which root portion 82 is planar. A user may deform the hole protector 80 so that the hole protector fits snugly into a hole of a required diameter. The hole protector may be supplied as a continuous sheet, and cut to a desired length and formed into a required shape. This embodiment has the advantage that a through hole of arbitrary shape and size may be protected. Furthermore, this embodiment avoids the necessity of maintaining a stock of preformed hole protectors of a range of sizes and shapes.

As in the previous embodiment, incisions 20 define a plurality of fingers or tabs 28 which can be plastically bent once the hole protector 80 has been bent into the shape required to fit a through hole.

Figure 4 shows a cross section of the hole protector 80. The flange surface 84 is oriented at right angles to root portion 82. To enable the hole protector 80 to be bent into an user-selected shape such as the hole protector 90 shown in Figure 5, the flange surface 84 comprises a plurality of incisions 86.

Claims

Claims: 1. A hole protector comprising an elongate root portion formed as, or deformable into, an annulus, a first flange portion projecting outwardly from one longitudinal edge of the root portion and a deformable second flange portion projecting from the opposite S edge of the root portion, wherein the second flange portion comprises a first plurality of incisions extending transversely from the longitudinal edge of the root portion and intersecting with an edge of the second flange portion, the first plurality of incisions defining a first plurality of tabs or fingers.
2. A hole protector as claimed in claim 1, wherein the annulus is circular and the first flange portion extends radially away from a central axis.
3. A hole protector as claimed in claim 1, wherein the elongate root portion is planar and is able to be deformed into an annulus by the user.
4. A hole protector as claimed in any previous claim comprising sheet metal.
5. A hole protector comprising a planar elongate root portion deformable into an annulus; a first flange portion projecting outwardly from one longitudinal edge of the root portion and a deformable second flange portion projecting from the opposite edge of the root portion, wherein the second flange portion comprises a first plurality of incisions extending transversely from the longitudinal edge of the root portion and intersecting with an edge of the second flange portion, the first plurality of incisions defining a first plurality of tabs or fingers.
6. A hole protector as claimed in claim S wherein the first flange portion comprises a second plurality of incisions extending transversely from the longitudinal edge of the root portion and intersecting with an edge of the first flange portion, the second plurality of incisions defining a second plurality of tabs or fingers.
7. A hole protector as claimed in claim S or claim 6 comprising sheet metal.
8. A hole protector as claimed in any of claims S to 7 wherein the second plurality of tabs or fingers is able to be plastically bent.
9. A hole protector for protecting the bore and edge of a through hole in a frangible sheet material, the hole protector comprising: a root 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 root 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.
10. A hole protector as claimed in any preceding claim, further comprising a surface coating.
11. A hole protector as claimed in claim 10, 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.
12. A method of protecting the bore and edge of a through hole in a sheet material comprising the steps of forming a hole protector to fit a shape of the through hole, the hole protector comprising: a planar elongate root portion deformable into an annulus, a first flange S portion projecting outwardly from one longitudinal edge of the root portion and a deformable second flange portion projecting from the opposite edge of the root portion, wherein the second flange portion comprises a first plurality of incisions extending transversely from the longitudinal edge of the root portion and intersecting with an edge of the second flange portion, the first plurality of incisions defining a first plurality of tabs or fingers; inserting the hole protector into the through hole; abutting the first flange portion against a first surface of the sheet material; deforming the first plurality of tabs or fingers so as to engage a second surface of the sheet material.
13. The method of claim 12 wherein the first flange portion comprises a second plurality of incisions extending transversely from the longitudinal edge of the root portion and intersecting with an edge of the first flange portion, the second plurality of incisions defining a second plurality of tabs or fingers.
14. 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.
15. A dry lined ceiling or wall as claimed in claim 14, further comprising a skim coat of plaster located over a visible surface thereof, the skim coat of plaster additional overlying at least part of the flange portion of the hole protector.S