FACE MOUNT INSERTS

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

FIELD OF THE INVENTION

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

BACKGROUND TO THE INVENTION

Various solutions have been proposed for reducing the size of an aperture through a panel, such as a ceiling or wall panel. In particular, problems exist where for example an existing aperture of a certain size has been made to accommodate, say a lighting fixture or a conduit to pass through the panel, but then that fixture or conduit is to be replaced with a smaller size which no longer needs the existing aperture size.

Indeed, where the aperture size for the replacement fixture or conduit or any other such device extending through an aperture is smaller than the existing aperture, there becomes a problem as to how to adequately reduce the aperture whilst also ameliorating the gap between the existing aperture side wall and the size of the device to extending through the panel.

Typically, an existing aperture may be in-filled by using a piece or pieces of the same (or different) panel material. However, the jointed region between such in-fill materials and the panel itself may be weak or may weaken or fail over time. For example, where there is an existing circular aperture through a ceiling panel and that existing aperture is to be reduced in size, an annular ring of material may be cut to be inserted into the existing aperture to provide the new aperture size. The joint between the outer surface of the annular ring and the panel may be connected to each other using joint tapes and layers of concealing material (e.g. plaster). However, such a solution still presents problems as the joint region may fail or weaken, leading to problems of cracked concealing material (plaster) or other finishing materials (e.g. paints).

SUMMARY OF THE INVENTION

It may therefore be an object of the present invention to provide for an insert component to be affixed to a panel to provide for a support structure about an aperture through said panel and/or which will go at least some way towards addressing the foregoing problems or which will at least provide the public with a useful choice. Such an insert is configured to receive or locate an item, such as a light fitting or fixture, or another item as may be described in this specification. It will be appreciated other items may be supported by the insert component as disclosed in this specification and need not be limited to those items which are specifically disclosed herein.

It may also be an object of the present invention to provide for an insert component capable of altering the shape and/or size of an existing aperture through a panel and/or which will go at least some way towards addressing the foregoing problems or which will at least provide the public with a useful choice.

In a first aspect there is provided an insert component to be affixed to a panel, said insert component comprising:

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

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

at least one first rim provided upon said first face and substantially about a perimeter of each said opening, and at least one second rim provided upon said first face and substantially about the perimeter of each said opening, wherein said first rim is located outwardly of said second rim relative to said perimeter of each said opening,

and wherein each of said first rim and said second rim are spaced from each other to define a channel region.

Each of said first rim and said second rim may be projections extending upwardly or away from said first face.

Each of said first rim and said second rim may be provided as projections upstanding from said first face.

The first rim may be of a first rim height relative to a first face surface of said flange portion, and said second rim may be of a second rim height relative to a first face surface of said flange portion.

The first rim height may be substantially equal to or less than said second rim height.

The second rim height may be substantially equal to or greater than said first rim height.

The first rim height may be less than said second rim height.

A height of the first rim may be about 1 mm, or about 2 mm, or about 3 mm, or about 4 mm, or about 5 mm, or about 6 mm, or about 7 mm, or about 8 mm, or about 9 mm, or about 10 mm, or may be less than about 10 mm, or less than about 8 mm, or less than about 6 mm, or less than about 4 mm, or less than about 2 mm, as measured from said first face of said body.

A height of the second rim may be about 2 mm, or about 3 mm, or about 4 mm, or about 5 mm, or about 6 mm, or about 7 mm, or about 8 mm, or about 9 mm, or about 10 mm, or about 11 mm, or about 12 mm, or may be less than about 12 mm, or less than about 10 mm, or less than about 8 mm, or less than about 6 mm, or less than about 4 mm, or less than about 2 mm, as measured from said first face of said body.

The channel region may have a floor or base defining a channel region depth, said floor or base being of a level, or providing for floor or base sections of a level, which may be one or more of:a level substantially equal to said first surface of said flange portion,a level substantially lower than said first surface of said flange portion,a level substantially higher than said first surface of said flange portion.

The channel may be of a pre-determined width, said width defined between facing side walls of each of said first rim and said second rim.

Said width may be sufficient to accommodate or receive a (curable) material.

The channel may be of a width that is greater than about 1 mm, or greater than about 2 mm, or greater than about 3 mm, or greater than about 4 mm, or greater than about 5 mm, or greater than about 10 mm, or greater than about 15 mm, or may be about 2 mm, or may be about 3 mm, or may be about 4 mm, or may be about 5 mm, or may be about 6 mm, or may be about 8 mm, or may be about 10 mm, or may be less than 10 mm.

The material may be a filler material (such as, but not limited to, one or more of: a plaster-type or render-type material, such as a material comprising of gypsum, lime or cement material, or is a material capable of being decorated or may be a material which can be finished, e.g. can be sanded to a finished surface, for a subsequent application of a decorative material, such as paint).

One or more of said at least one opening may further comprises of a ledge, said ledge providing a support surface extending substantially inwardly toward a centre of said opening.

The support surface may be a surface facing the same direction as said first face of said body.

The support surface may be a substantially planar surface.

The support surface may provide a surface upon which an item is seatable.

The item may be a light fixture or fitting, or may be a smoke alarm or smoke detector or other fittings or fixtures.

One or more projections may be provided upon said second face of said body.

The projections upon said second face of said body may extend a pre-determined height or distance away from said second face.

The projections upon said second face may be provided to, in-use, space said body, via said second face, away from a surface upon which said second face is to be located.

The projections upon said second face may be provided to, in-use, provide a gap or a space between said second face and a surface upon which said second face is to be located.

The space or gap may provide a void into which a (optionally curable) material can be in-filled.

The one or more projections may be provided upon said second face of said body are distributed about said second face.

The one or more projections may be provided upon said second face of said body are distributed substantially evenly or equidistantly from each other and about said second face.

There may be six projections provided upon said second face of said body.

The projections upon the second face may be of a pre-determined height or extend a distance away from the second face of about 0.5 mm, or about 1 mm, or may be less than about 5 mm, or less than about 4 mm, or less than about 3 mm, or less than about 2 mm, or less than about 1 mm, or less than about 0.5 mm.

The flange may extend substantially about a part, or parts, or substantially an entirety, of said perimeter of said body.

The flange may extend as two opposing sides of said body (i.e. there are cut-off or straight side portions).

The flange may comprise one or more apertures, said apertures extending through said body.

The apertures may provide for a void through said body.

The apertures may be distributed about said flange.

The second face of said body may be a substantially planar surface.

The second face of said body may be substantially planar, apart from one or more projections provided upon said second face of said body.

The body may be substantially circular, oval or of a rectilinear perimeter shape.

One or more of said at least one opening(s) may be substantially circular, oval or of a rectilinear perimeter shape.

The ledge may be substantially circular, oval or of a rectilinear perimeter shape.

A diameter of an inner perimeter of said second rim may be about 25 mm to about 104 mm, or may be about 76 mm, or may be about 86 mm, or about 102 mm, or about 103 mm, or about 104 mm, or about 105 mm, or about 106 mm, or may be about 160 mm, or may be about 200 mm, or may be greater than about 10 mm, or greater than about 20 mm, or greater than about 25 mm, or greater than about 30 mm, or greater than about 35 mm, or greater than about 40 mm, or greater than about 50 mm, or greater than about 85 mm, or greater than about 100 mm, or greater than about 105 mm, or greater than about 125 mm, or greater than about 150 mm, or greater than about 175 mm, or greater than about 200 mm, or greater than about 300 mm, or greater than about 400 mm.

The flange may be detachable or attachable or integral with said body.

The first rim or said second rim, or both, may be detachable or attachable or with said body.

The ledge may be detachable or attachable or integral with said body.

The projections provided upon said second face of said body may detachable or attachable or integral with said body.

A separate component piece, such as a plate-type component piece, may be provided for seating upon the ledge.

The separate component piece may be provided as a plate-type component piece comprising of one or more apertures.

The separate component piece may be provided as a plug or cap for the insert component.

The separate component piece is substantially planar and of a substantially constant thickness.

The thickness of the separate component piece may be sufficient so as to align or be substantially matched with the second rim

The second rim may be of about a 2 mm height, the first rim may be of about a 1 mm height.

The separate component piece may be of about a 2 mm thickness.

In a second aspect there is provided a structure formed in-situ with a panel, wherein an insert as defined in the first aspect or according to any preceding statement is affixed to a face of a panel.

A rebate is formed in said face of said panel, said rebate being of a depth to receive said insert, such that an end of said second rim is substantially level or aligned with said face of said panel, or an intended level of a finished or decorated surface of said panel.

It is further contemplated that where a light fitting or fixture is described, said light fitting may be substituted with any other fitting or component to be installed into a panel, such as, speakers, furniture, ducts, piping, components of alarm or safety systems (e.g., smoke detectors, gas detectors, infrared motion detectors) or any other outlet, utility or appliance.

It is further contemplated that any such fittings or components or systems to be installed may be retrofitted with suitable adaptors for installing into a body or assembly as described in any one of the preceding aspects or embodiments.

It is further contemplated that an assembly may comprise the body as described herein, and in particular with reference to any one or more of the preceding aspects or embodiments.

The invention described herein provides for at least two separate rims, being of the same or different height projections of the first face of the body, where at least the first rim provides for a first reference height and the second rim provides for a second reference height. The reference heights being made with reference to the first face of the body or with reference to a face of a panel into which the insert is to be affixed or received.

In certain embodiments, the first rim is of a lower or smaller height or size then the second rim. In this manner, where for example a (curable) material such as a plaster is to be applied over the insert (for example to affixed of mechanically engage the insert with the panel to which it is to be affixed), a first application of a material can be made upon the insert, and an amount of material can be applied such that the material is applied to a thickness to align with the first rim. A second or subsequent layer of material may then be applied or coated, and this may be to a thickness to align with the second rim.

It will be appreciated the body of this invention may also be utilised for use in altering or reducing or amending the shape or dimension of other aspects of an aperture or opening through a panel.

In a third aspect there is provided an insert component to be affixed to a panel, said insert component comprising:

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

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

wherein at least a portion at the perimeter of the body is adjustable and/or adaptable toward and/or away from the at least one opening.

The perimeter is moveable, preferably radially, so as to provide a biasing means for retaining the body in a rebate formed in the face of a panel, the rebate being of a depth to receive said insert.

In a particular form the rebate is formed in a ceiling structure and the at least one opening is adapted to receive a lighting fixture or the like ceiling fixture such as a sensor. In a preferred form the rebate is sized so as to receive the insert with minimal clearance such that the adjustable perimeter is adjustable/adaptable to engage a side of the rebate.

A suitable retention means for adjusting the perimeter may be by way of at least one resilient element located at the perimeter of the body, adapted to provide an outward bias to retain the body of the insert in a rebate. When in a retained state a user can apply a (curable) material such as a plaster over the insert. The retention means can alternatively be termed a biasing element, perimeter expander, spring-biased member or any combination of these terms.

The resilient element may include an outward projection beyond the main perimeter. The projection may be of bevelled/tapered or spike form to engage into a surface of the rebate, in use.

The insert of the third aspect may incorporate and be combined with any or all additional features described above in relation to the first or second aspect of the invention. For example, the insert of the invention may further include projections or bumps on the rebate-facing face of the body so as to provide a spacing function of the body from the rebate inner surface and allow flow of adhesive and/or curable material such as plaster. In a fourth aspect there is provided an insert component to be affixed to a panel, said insert component comprising:

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

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

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

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

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

The rim may be a projection extending upwardly or in a direction away from said first face and said second face.

The rim may be provided as a projection upstanding from said first face.

The channel may be provided as a recess in said first face.

The channel may be located between the rim and said flange portion.

The rim may form a first channel wall of said channel.

A height of said first channel wall may be substantially equal to or greater than a second channel wall, and the second channel wall may be located outwardly of said first channel wall relative to said perimeter of each said opening.

A height of the rim may be about 2 mm, or about 3 mm, or about 4 mm, or about 5 mm, or about 6 mm, or about 7 mm, or about 8 mm, or about 9 mm, or about 10 mm, or about 11 mm, or about 12 mm, or may be less than about 12 mm, or less than about 10 mm, or less than about 8 mm, or less than about 6 mm, or less than about 4 mm, or less than about 2 mm, as measured from said first face of said body.

The channel region may have a floor or base defining a channel region depth, said floor or base being of a level, or providing for floor or base sections of a level substantially lower than said first face of said body and/or said flange portion.

A depth of the channel may be about 1 mm, or about 2 mm, or about 3 mm, or about 4 mm, or about 5 mm, or about 6 mm, or about 7 mm, or about 8 mm, or about 9 mm, or about 10 mm, or may be less than about 10 mm, or less than about 8 mm, or less than about 6 mm, or less than about 4 mm, or less than about 2 mm, as measured from said first face of said body.

The channel may be of a pre-determined width, said width defined between said first channel wall and said second channel wall.

The width and/or said depth of said channel may be sufficient to accommodate or receive a (curable) material.

The width of the channel may be greater than about 1 mm, or greater than about 2 mm, or greater than about 3 mm, or greater than about 4 mm, or greater than about 5 mm, or greater than about 10 mm, or greater than about 15 mm, or is about 2 mm, or is about 3 mm, or is about 4 mm, or is about 5 mm, or is about 6 mm, or is about 8 mm, or is about 10 mm, or is less than 10 mm.

The material may be a filler material (such as, but not limited to, one or more of: a plaster-type or render-type material, such as a material comprising of gypsum, lime or cement material, or is a material capable of being decorated or may be a material which can be finished, e.g. can be sanded to a finished surface, for a subsequent application of a decorative material, such as paint).

One or more of said at least one opening may further comprise of a ledge, said ledge providing a support surface extending substantially inwardly toward a centre of said opening.

The support surface may be a surface facing the same direction as said first face of said body.

The support surface may be a substantially planar surface.

The support surface may comprise a channel or recess.

The support surface of said ledge may be recessed from said rim, or may be of a reduced height relative to said rim.

The support surface may provide a surface upon which an item is seatable.

The item may be one of: a light fixture or fitting, a smoke or fire alarm or detector, a sprinkler, an audio speaker, a ceiling mounted sensor, or other fittings or fixtures or devices.

The second face may comprise an inner portion and an outer portion.

The outer portion may substantially correspond with said flange portion, and the inner portion may substantially correspond with said channel and said rim.

The inner portion may be a raised or stepped region, raised or stepped in a direction to accommodate said channel.

A sidewall may define a step between said outer portion and said inner portion, and may be provided as a guide for locating said body into an aperture of a panel.

The outer portion may be substantially planar.

The outer portion comprises of an adhesive, projection or fastener, and may be adhered or affixed to a surface of a panel in use.

The outer portion may comprise one or more projections, the one or more projections being of a bevelled, tapered and/or of a spiked form.

The one or more projections may extend in a direction away from said second face, or in a direction toward a surface of a panel to which said insert is to be affixed.

The one or more projections may provide for a mechanical engagement or attachment with the panel.

The one or more projections may be provided as an array about the second face of said outer portion.

The flange portion may have a relatively greater wall thickness in the region adjacent to or at said channel, and may be of a relatively reduced wall thickness in a region adjacent to or at said perimeter of said body.

The flange portion may be of a wall thickness of about 0.5 mm in a region adjacent to or at said perimeter of said body.

The flange portion may be of a wall thickness of about 1 mm in a region adjacent to or at said channel.

The flange portion may be substantially tapered in a reducing wall thickness, said wall thickness reducing in a direction as said flange portion extends substantially radially outwardly from said channel.

The first face may comprise said rim defining a first projected height, said flange portion at or substantially adjacent to said channel defining a second projected height, and said flange portion at or substantially adjacent to said perimeter defining a third projected height.

The rim may define a first projected height of said first face, said flange portion at or substantially adjacent to said channel may define a second projected height of said first face, and said flange portion at or substantially adjacent to said perimeter may define a third projected height of said first face.

The third projected height may be less than said second projected height.

The third projected height may be less than said first projected height.

The second projected height may be less than said first projected height.

The third projected height may be less than said second projected height, and said second projected height may be less than said first projected height.

The flange portion may slope from said first projected height to said third projected height.

An outer edge of said flange portion may define said perimeter of said body.

The first face of said outer edge may comprise a chamfered edge portion.

The first face may further comprise said support surface of said ledge defining a fourth projected height.

The fourth projected height may be less than said first projected height, or matches the height of the first projected height.

The flange portion may extend substantially radially outwardly of said channel.

The flange portion may extend substantially about a part, or parts, or substantially an entirety, of said perimeter of said body.

The flange portion may extend as two opposing sides of said body (i.e. is cut-off sides), or wherein two opposing sides of said flange portion are substantially parallel.

The flange portion may comprise one or more apertures, said apertures extending through said body.

The apertures may provide for a void through said body.

The apertures may be distributed about said flange portion.

The channel may comprise one or more channel apertures, and said apertures may extend through said body.

The channel apertures may provide for a void through said body.

The channel apertures may be distributed about said channel.

The channel may comprise one or more ribs.

The one or more ribs may extend across said channel.

The one or more ribs may be strengthening members.

The one or more ribs may provide for a strengthening structure between a wall of said rim and a wall of said flange portion.

The one or more ribs may extend substantially across said channel or said floor of said channel, or between sidewalls of said channel.

The one or more ribs may be distributed about said channel.

The one or more ribs may be of a height below the first face, or said one or more ribs may be provided of a height recessed from said first face, or of said flange portion.

The body may be substantially circular, oval or of a rectilinear perimeter shape.

One or more of said at least one opening(s) may be substantially circular, oval or of a rectilinear perimeter shape.

The ledge may be substantially circular, oval or of a rectilinear perimeter shape.

A diameter of an inner perimeter of said rim may be about 25 mm to about 104 mm, or is about 76 mm, or about 86 mm, or about 102 mm, or about 103 mm, or about 104 mm, or about 105 mm, or about 106 mm, or may be about 160 mm, or may be about 200 mm, or is greater than about 10 mm, or greater than about 20 mm, or greater than about 25 mm, or greater than about 30 mm, or greater than about 35 mm, or greater than about 40 mm, or greater than about 50 mm, or greater than about 85 mm, or greater than about 100 mm, or greater than about 105 mm, or greater than about 125 mm, or greater than about 150 mm, or greater than about 175 mm, or greater than about 200 mm, or greater than about 300 mm, or greater than about 400 mm.

The flange may be detachable or attachable or integral with said body.

The rim or the channel, or both, may be detachable or attachable or integral with said body.

The ledge may be detachable or attachable or integral with said body.

A separate component piece, such as a plate-type component piece, may be provided for seating upon the ledge.

The separate component piece may be provided as a plate-type component piece comprising of one or more apertures.

The separate component piece may be provided as a plug or cap for the insert component.

The separate component piece may be substantially planar and of a substantially constant thickness.

The insert as defined in any of the first, second, third, fourth, or fifth aspects may be affixed to a face of a panel.

A rebate may be formed in said face of said panel, said rebate being of a depth to receive said insert, such that an end of said rim is substantially level or aligned with said face of said panel, or an intended level of a finished or decorated surface of said panel.

A structure may be formed in-situ with a panel, and said insert as defined in any of the first, second, third, fourth, or fifth aspects may be affixed to a face of the panel, and a rebate may be formed in said face of said panel and sized so as to receive the insert such that the at least a portion at the perimeter of the body is configured to extend to engage a side of the rebate and retain the insert therewithin the rebate.

The insert of the fourth aspect may incorporate and be combined with any or all additional features described above in relation to the first or second or third aspect, or with any or all additional features described below in relation to the fifth aspect of the invention. For example, the insert of the invention may further include projections or bumps on the rebate-facing face of the body so as to provide a spacing function of the body from the rebate inner surface and allow flow of adhesive and/or curable material such as plaster. Additionally, the insert may comprise one or more resilient elements.

In a fifth aspect there is provided an insert component to be affixed to a panel, said insert component comprising:

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

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

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

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

The rim may be a projection extending upwardly or in a direction away from said first face and said second face.

The rim may be provided as a projection upstanding from said first face.

The channel may be provided as a recess in said first face.

The channel may be located between the rim and said flange portion.

The rim may form a first channel wall of said channel.

A height of said first channel wall may be substantially equal to or greater than a second channel wall, and the second channel wall may be located outwardly of said first channel wall relative to said perimeter of each said opening.

A height of the rim may be about 2 mm, or about 3 mm, or about 4 mm, or about 5 mm, or about 6 mm, or about 7 mm, or about 8 mm, or about 9 mm, or about 10 mm, or about 11 mm, or about 12 mm, or may be less than about 12 mm, or less than about 10 mm, or less than about 8 mm, or less than about 6 mm, or less than about 4 mm, or less than about 2 mm, as measured from said first face of said body.

The channel region may have a floor or base defining a channel region depth, said floor or base being of a level, or providing for floor or base sections of a level substantially lower than said first face of said body and/or said flange portion.

A depth of the channel may be about 1 mm, or about 2 mm, or about 3 mm, or about 4 mm, or about 5 mm, or about 6 mm, or about 7 mm, or about 8 mm, or about 9 mm, or about 10 mm, or may be less than about 10 mm, or less than about 8 mm, or less than about 6 mm, or less than about 4 mm, or less than about 2mm, as measured from said first face of said body.

The channel may be of a pre-determined width, said width defined between said first channel wall and said second channel wall.

The width and/or said depth of said channel may be sufficient to accommodate or receive a (curable) material.

The width of the channel may be greater than about 1 mm, or greater than about 2 mm, or greater than about 3 mm, or greater than about 4 mm, or greater than about 5 mm, or greater than about 10 mm, or greater than about 15 mm, or is about 2 mm, or is about 3 mm, or is about 4 mm, or is about 5 mm, or is about 6 mm, or is about 8 mm, or is about 10 mm, or is less than 10 mm.

The material may be a filler material (such as, but not limited to, one or more of: a plaster-type or render-type material, such as a material comprising of gypsum, lime or cement material, or is a material capable of being decorated or may be a material which can be finished, e.g. can be sanded to a finished surface, for a subsequent application of a decorative material, such as paint).

One or more of said at least one opening may further comprise of a ledge, said ledge providing a support surface extending substantially inwardly toward a centre of said opening.

The support surface may be a surface facing the same direction as said first face of said body.

The support surface may be a substantially planar surface.

The support surface may comprise a channel or recess.

The support surface of said ledge may be recessed from said rim, or may be of a reduced height relative to said rim.

The support surface may provide a surface upon which an item is seatable.

The item may be one of: a light fixture or fitting, a smoke or fire alarm or detector, a sprinkler, an audio speaker, a ceiling mounted sensor, or other fittings or fixtures or devices.

The second face may comprise an inner portion and an outer portion.

The outer portion may substantially correspond with said flange portion, and the inner portion may substantially correspond with said channel and said rim.

The inner portion may be a raised or stepped region, raised or stepped in a direction to accommodate said channel.

A sidewall may define a step between said outer portion and said inner portion, and may be provided as a guide for locating said body into an aperture of a panel.

The outer portion may be substantially planar.

The outer portion comprises of an adhesive, projection or fastener, and may be adhered or affixed to a surface of a panel in use.

The outer portion may comprise one or more projections, the one or more projections being of a bevelled, tapered and/or of a spiked form.

The one or more projections may extend in a direction away from said second face, or in a direction toward a surface of a panel to which said insert is to be affixed.

The one or more projections may provide for a mechanical engagement or attachment with the panel.

The one or more projections may be provided as an array about the second face of said outer portion.

The flange portion may have a relatively greater wall thickness in the region adjacent to or at said channel, and may be of a relatively reduced wall thickness in a region adjacent to or at said perimeter of said body.

The flange portion may be of a wall thickness of about 0.5 mm in a region adjacent to or at said perimeter of said body.

The flange portion may be of a wall thickness of about 1 mm in a region adjacent to or at said channel.

The flange portion may be substantially tapered in a reducing wall thickness, said wall thickness reducing in a direction as said flange portion extends substantially radially outwardly from said channel.

The first face may comprise said rim defining a first projected height, said flange portion at or substantially adjacent to said channel defining a second projected height, and said flange portion at or substantially adjacent to said perimeter defining a third projected height.

The rim may define a first projected height of said first face, said flange portion at or substantially adjacent to said channel may define a second projected height of said first face, and said flange portion at or substantially adjacent to said perimeter may define a third projected height of said first face.

The third projected height may be less than said second projected height.

The third projected height may be less than said first projected height.

The second projected height may be less than said first projected height.

The third projected height may be less than said second projected height, and said second projected height may be less than said first projected height.

The flange portion may slope from said first projected height to said third projected height.

An outer edge of said flange portion may define said perimeter of said body.

The first face of said outer edge may comprise a chamfered edge portion.

The first face may further comprise said support surface of said ledge defining a fourth projected height.

The fourth projected height may be less than said first projected height, or matches the height of the first projected height.

The flange portion may extend substantially radially outwardly of said channel.

The flange portion may extend substantially about a part, or parts, or substantially an entirety, of said perimeter of said body.

The flange portion may extend as two opposing sides of said body (i.e. is cut-off sides), or wherein two opposing sides of said flange portion are substantially parallel.

The flange portion may comprise one or more apertures, said apertures extending through said body.

The apertures may provide for a void through said body.

The apertures may be distributed about said flange portion.

The channel may comprise one or more channel apertures, and said apertures may extend through said body.

The channel apertures may provide for a void through said body.

The channel apertures may be distributed about said channel.

The channel may comprise one or more ribs.

The one or more ribs may extend across said channel.

The one or more ribs may be strengthening members.

The one or more ribs may provide for a strengthening structure between a wall of said rim and a wall of said flange portion.

The one or more ribs may extend substantially across said channel or said floor of said channel, or between sidewalls of said channel.

The one or more ribs may be distributed about said channel.

The one or more ribs may be of a height below the first face, or said one or more ribs may be provided of a height recessed from said first face, or of said flange portion.

The body may be substantially circular, oval or of a rectilinear perimeter shape.

One or more of said at least one opening(s) may be substantially circular, oval or of a rectilinear perimeter shape.

The ledge may be substantially circular, oval or of a rectilinear perimeter shape.

A diameter of an inner perimeter of said rim may be about 25 mm to about 104 mm, or is about 76 mm, or about 86 mm, or about 102 mm, or about 103 mm, or about 104 mm, or about 105 mm, or about 106 mm, or may be about 160 mm, or may be about 200 mm, or is greater than about 10 mm, or greater than about 20 mm, or greater than about 25 mm, or greater than about 30 mm, or greater than about 35 mm, or greater than about 40 mm, or greater than about 50 mm, or greater than about 85 mm, or greater than about 100 mm, or greater than about 105 mm, or greater than about 125 mm, or greater than about 150 mm, or greater than about 175 mm, or greater than about 200 mm, or greater than about 300 mm, or greater than about 400 mm.

The flange may be detachable or attachable or integral with said body.

The rim or the channel, or both, may be detachable or attachable or integral with said body.

The ledge may be detachable or attachable or integral with said body.

A separate component piece, such as a plate-type component piece, may be provided for seating upon the ledge.

The separate component piece may be provided as a plate-type component piece comprising of one or more apertures.

The separate component piece may be provided as a plug or cap for the insert component.

The separate component piece may be substantially planar and of a substantially constant thickness.

The insert as defined in any of the first, second, third, fourth, or fifth aspects may be affixed to a face of a panel.

A rebate may be formed in said face of said panel, said rebate being of a depth to receive said insert, such that an end of said rim is substantially level or aligned with said face of said panel, or an intended level of a finished or decorated surface of said panel.

A structure may be formed in-situ with a panel, and said insert as defined in any of the first, second, third, fourth, or fifth aspects may be affixed to a face of the panel, and a rebate may be formed in said face of said panel and sized so as to receive the insert such that the at least a portion at the perimeter of the body is configured to extend to engage a side of the rebate and retain the insert therewithin the rebate.

The insert of the fifth aspect may incorporate and be combined with any or all additional features described above in relation to the first or second or third or fourth aspect of the invention. For example, the insert of the invention may further include projections or bumps on the rebate-facing face of the body so as to provide a spacing function of the body from the rebate inner surface and allow flow of adhesive and/or curable material such as plaster. Additionally, the insert may comprise one or more resilient elements.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

This invention provides for an insert component1, that can provide for a member in the form of a body2, to which a fitting or fixture may be mounted or seated upon and supported. Such a member can provide for a particular structural support for a fitting or fixture to be supported thereon or thereto.

The insert component1can also provide for a particular or pre-determined (i.e. a pre-formed) dimensioned or shaped opening. Such an opening providing for receipt of a fitting or fixture. Such a particularly dimensioned or shaped opening provided by the insert component may facilitate the re-sizing or alteration in shape of an existing aperture in a panel, the insert component capable of receiving such a fitting of fixture.

The insert component (as described herein) can be located or positioned into a rebate or recessed region of a panel, such that the insert component can be subsequently mechanically fixed into place, for example by application of one or more layers of material, such as a curable material like plaster or other curable medium or adhesives. In this manner, the insert component can be integrated into the panel. The insert component then provides a particular structure for assisting with such an integration and as a support for a fixture of fitting.

This invention also provides for a relatively uncomplicated system for reducing the geometry, such as shape or size of an existing aperture, whilst as the same time provides a platform upon which materials, such as concealing compositions—e.g. plaster, paint or other fillers or finishes, may be applied to conceal the joint region between the insert component and the surrounding panel.

It will also be appreciated the present invention may be utilised for improving or strengthening the aperture or opening cut or made in a building panel to receive a fitting, such as a light fitting (or any other outlet or utility requiring an aperture through a building panel) or a wall socket (such as for electrical outlets or indeed any other outlet requiring an aperture through a building panel). For example, the existing aperture or opening referred to here may be the aperture which is initially cut or made in a building panel to then receive a fitting or fixture.

The insert component of the invention facilitates an improvement in the strength of the building panel around an aperture or opening through the panel and any finishes made about the aperture so cut or made, and in this way can help to minimise possible “break-out” in which the materials used around the aperture or opening are compromised as to their structural integrity due to forces imposed upon them, for example by a light fitting imparting a force on a building panel about the aperture. “Break out” may result in cracking of plaster or paint or other unsightly effects in decorative finishes around the aperture.

The insert component can facilitate the alteration in the shape or size of an aperture or opening through a panel, for example a building panel such as a ceiling or a wall. The following description is provided as exemplary of the invention, and is made with reference to the accompanying drawings.

Accordingly, described below are particular details of one embodiment of an insert component.

In one embodiment there is provided an insert component1to be affixed to, for example, a panel (P, seeFIG. 7). The insert component1comprises a body2. The body2includes a first face3and a second face4. The body1defines at least one opening5that extends between the first face3and the second face4. The at least one opening5is positioned within a perimeter (such as an outer perimeter) of the body1. A flange portion6extending substantially radially outwardly from one or each of said at least one opening5. At least one first rim7is provided upon the first face3and substantially about a perimeter of each opening5. At least one second rim8is provided upon the first face3and substantially about the perimeter of each opening5. The first rim7is located outwardly of the second rim8, relative to the perimeter of each opening5. Each of the first rim7and the second rim8are spaced from each other to define a channel region9therebetween.

While a single opening5is shown in the accompanying figures, it will be appreciated that the body2may be of any shape or size and could accommodate any number of openings, where one or more of those openings can each be provided with the first rim and the second rim with the channel region located between those rims. In this manner, the number of openings5in a body2may be customised according to the number of fittings or fixtures which are to be received by the insert component1.

As is for example shown in the figures, each of the first rim7and second rim8may be of the form of projections which extend in a direction upwardly or away from said first face3of the body1. That is, the first and second rims are provided as projections upstanding from the first face3.

The first rim7can be of a first rim height7H relative to the first face3surface of said flange portion6, while the second rim8can be of a second rim height8H relative to a first face3surface of the flange portion6.

The first rim height7H can be substantially equal to or less than the second rim height8H. Expressed in an alternative manner, the second rim height8H can be substantially equal to or greater than the first rim height7H.

Depending on the situational use, the first rim height7H may be of a height that is less than the second rim height8H.

In one example, the height7H of the first rim7may be about 1 mm, as measured from the first face3of the body1to the most distal tip or end of the first rim7. In various other embodiments, a height of the first rim may be about 1 mm, or about 2 mm, or about 3 mm, or about 4 mm, or about 5 mm, or about 6 mm, or about 7 mm, or about 8 mm, or about 9 mm, or about 10 mm, or may be less than about 10 mm, or less than about 8 mm, or less than about 6 mm, or less than about 4 mm, or less than about 2 mm, as measured from said first face of said body.

In another example, the height8H of the second rim8may be about 2 mm, as measured from the first face3of the body1to the most distal tip or end of the second rim7. In various other embodiments, a height of the second rim may be about 2 mm, or about 3 mm, or about 4 mm, or about 5 mm, or about 6 mm, or about 7 mm, or about 8 mm, or about 9 mm, or about 10 mm, or about 11 mm, or about 12 mm, or may be less than about 12 mm, or less than about 10 mm, or less than about 8 mm, or less than about 6 mm, or less than about 4 mm, or less than about 2 mm, as measured from said first face of said body.

The channel region9has a floor or base which defines a channel region depth9H. The floor or base of the channel region9is of a level, or provides for a floor or base sections of a level, which may be one or more of:

a level that is substantially equal to the level of the first surface3or of the flange portion6,

a level that is substantially lower than the level of the first surface3or of said flange portion6,

a level substantially higher than the level of the first surface3or of the flange portion6.

The channel may be configured to be provided with a continuous floor or base, or the floor or base may be of a discontinuous form (i.e. the floor or base may comprise of apertures).

The depth of the channel region is advantageously sufficient so as to allow for a depth or thickness of material to be applied and to in-fill the channel region9.

The channel may be of a width that is greater than about 1 mm, or greater than about 2 mm, or greater than about 3 mm, or greater than about 4 mm, or greater than about 5 mm, or greater than about 10 mm, or greater than about 15 mm, or may be about 2 mm, or may be about 3 mm, or may be about 4 mm, or may be about 5 mm, or may be about 6 mm, or may be about 8 mm, or may be about 10 mm, or may be less than 10 mm.

The depth and/or width of the channel region9can provide for a region of increased material, and accordingly can provide for a stronger bond or stronger plaster edge or edge of material which is joining the insert component1to the surrounding panel material.

The channel region9is of a pre-determined width. This width can be defined between the facing side walls of each of the first rim7and the second rim8.

The width of the channel region is sufficient so as to accommodate or receive a (curable) material.

The material may be a filler material, such as, but not limited to, one or more of: a plaster-type or render-type material, such as a material comprising of gypsum, lime or cement material, or is a material capable of being decorated or may be a material which can be finished, e.g. can be sanded to a finished surface, for a subsequent application of a decorative material, such as paint.

The insert component1can optionally also comprises of a ledge10.

A ledge10can be provided for one or more, or each of, the at least one opening(s)5of in the body2.

The ledge10can provide a support surface11that extends substantially inwardly toward a centre of the opening5to which the ledge10is provided. That is, one or more, or all, of the openings through the body2can be provided with a ledge10, each such ledge providing its own support surface11.

The support surface11allows for the seating or receipt thereon of a fixture or fitting or another item or device which is to be received within the opening5. The ledge10with its support surface11provides a structure upon which the fixture or fitting or item or device can be received or seated thereon.

The support surface11can be a surface of the ledge which faces in substantially the same direction as the first face3of the body2. It will be appreciated that the support surface of the ledge may be another surface of the ledge10, and is not limited necessarily to being the surface identified as item11. For example, a rear side surface labelled as item12may be used as the support surface, but in that case such a surface12would face in a different direction.

The support surface (whether as a surface11or12) can be a substantially planar or flat surface, although it will be appreciated that other formations (not shown) may be provided upon the surface (11or12) to facilitate a suitable seating of a fixture or fitting or item or device.

The support surface advantageously provides a surface or a platform upon which an item is received thereon or is seatable.

The fixture or fitting may be a light fixture or a light fitting, or may be a smoke alarm or smoke detector or other fittings or fixtures or devices.

The second face4of the body2can comprises one or more projections13.

The projections13provided on the second face4of the body2can extend a pre-determined height or distance away from the second face4.

The projections13, in-use, allowing for a spacing of the second face4and therefore the body2, away from a surface (e.g. a surface of a panel) upon which the second face is to be located. That is, the projections13provide or facilitate a gap or a space to be formed between the second face4and the surface upon which the body is to be located (e.g. panel surface onto which the insert component is to be positioned or located).

It is the space or gap formed by the projections13which mean a void is created between the body2and the surface to which the insert component is to be affixed into which a (optionally curable) material can be in-filled.

The one or more projections13can be distributed about the second face4. The distribution may be in a manner so as to substantially evenly support or space the second face of the body2from the surface upon which the insert component is to be affixed. In various embodiments, the projections13may be distributed substantially evenly or equidistantly from each other and about the second face4.

In one particular embodiment there may be six projections provided upon the second face of the body2, although it will be appreciated that any number of projections may be provided.

The projections upon the second face may be of a pre-determined height or extend a distance away from the second face of about 0.5 mm, or about 1 mm, or may be less than about 5 mm, or less than about 4 mm, or less than about 3 mm, or less than about 2 mm, or less than about 1 mm, or less than about 0.5 mm.

The flange portion6can extend substantially about a part, or parts, or substantially an entirety, of the perimeter, such as the outer perimeter, of the body2.

The flange portion may be of any size, shape or dimension suitable for providing a region which extends the surface area for affixation of the insert component1to a surface.

Particularly where a curable medium or material (e.g. plaster) is used for affixation of the insert component1to a surface, an increase in surface area of the insert component may be advantageous for increasing or improving the surface area for a mechanical adhesion.

The flange portion6can be provided as two opposing sides of said body (i.e. there are cut-off or straight side portions).

The flange portion6can have one or more apertures14, the apertures14extending through the body2. The apertures14can provide for voids through the body2.

The apertures14can be distributed about the flange portion.

The apertures14can be a series of similar sizes and shapes, or may be the same or may be differently sized and shaped.

The apertures14allow for a curable material or medium, when applied to the first face3, to be pushed through the apertures14so as to fill and be provided in contact with a surface of a panel to which the insert component is being affixed.

Where for example the projections13are provided, then the apertures14also allow for the material or medium to be applied and be applied through to fill in the space or gap or void created by the projections13standing the second face4off of the surface of a panel. This allows for greater amounts of material or medium to be applied and to be provided for improved mechanical adhesion or connection between the surface and the insert component.

Optionally, a sufficient amount or quantity of material or medium can be applied so as to encapsulate the insert component1and to retain the insert component in-situ.

The second face4of the body2may be provided as a substantially planar surface, apart from the optional one or more projections13which would otherwise be provided thereon.

However, other formations (not shown) may be provided on the second face4to facilitate further stand-off of the body from a surface to which the insert component is to be affixed, or may comprise of yet other functional formations which facilitate improve or greater mechanical connection of the insert component1to a surface of a panel.

It will be appreciated that the insert component1may be of any shape or dimension, but particularly preferably may be shapes which are substantially circular, oval or of a rectilinear perimeter shape.

It will be appreciated that the opening5may be of any shape or dimension, but particularly preferably may be shapes which may be substantially circular, oval or of a rectilinear perimeter shape.

It will be appreciated that the ledge10may be of any shape or dimension, but particularly preferably may be shapes which are substantially circular, oval or of a rectilinear perimeter shape, or are suitable shaped and dimensioned relative to the shape and dimension of an associated opening5.

A diameter of an inner perimeter of said second rim may be about 25 mm to about 104 mm, or may be about 76 mm, or may be about 86 mm, or about 102 mm, or about 103 mm, or about 104 mm, or about 105 mm, or about 106 mm, or may be about 160 mm, or may be about 200 mm, or may be greater than about 10 mm, or greater than about 20 mm, or greater than about 25 mm, or greater than about 30 mm, or greater than about 35 mm, or greater than about 40mm, or greater than about 50 mm, or greater than about 85 mm, or greater than about 100 mm, or greater than about 105 mm, or greater than about 125 mm, or greater than about 150 mm, or greater than about 175 mm, or greater than about 200 mm, or greater than about 300 mm, or greater than about 400 mm. The diameter may be of any diameter, but the above diameters may have particular application utility.

The flange portion6can be provided as a component which is detachable or attachable or that is integral with the body2.

The first rim7or the second rim8, or both first and second rims, can be provided as a component or as each separate components, which are separately or in a combined manner, detachable or attachable or with the body2.

The ledge10can be provided as a component that is detachable or attachable or that is integral with the body2.

The projections13can be provided as separate components, or a combined component, for provision upon the second face4of the body2, that is detachable or attachable or that is integral with the body2.

As for example shown inFIG. 8, a separate component piece15can be provided. Such a component piece15may for example be in the form of a plate-type component piece. Such a separate component piece15may be provided for seating upon the ledge10.

The separate component15piece may comprise one or more apertures16, which are configured to allow for the ingress of a material or medium as described elsewhere herein.

The separate component piece15can be provided as a plug or cap for the insert component1. In this way, the insert component1can be put into position with respect to a panel P, and then the component piece15can be separately installed upon the insert component1. It will be appreciated that the component piece15may be provided with additional formations to facilitate an improved quality of connection with the insert component or with a material or medium which is to be applied thereon.

In one embodiment, the separate component piece15is substantially planar and of a substantially constant thickness. The thickness of the separate component piece may be sufficient so as to align or be substantially matched with the second rim.

In a particular example, the second rim may be of about a 2 mm height, the first rim may be of about a 1 mm height. Optionally, where a component piece15is also used, then the separate component piece may be of about a 2 mm thickness.

FIG. 9illustrates the assembly or relative positioning of the component piece15upon the ledge of the insert component1.

As for example shown inFIG. 7, an insert component1can be positioned into a rebated region R of a panel P. The insert component1can then be mechanically affixed in place, for example by application of one or more layers of material or medium M.

According to the above description, there is provided herein for an insert component1. The insert component1has desirable utility in providing for a structure to assist with the support of a fixture or fitting or other item or device which is to be provided in a panel (such as a ceiling or wall).

In one preferred mode of installation, the insert component1is to be positioned within a rebated region of a panel surface. The rebate being of sufficient depth to accommodate the insert component1. The rebate can be of a depth such that the tip or distal end of the second rim8is substantially in-line with the surface of the panel into which the insert component1is to be received. That is, a rebate can be formed in a face of a panel, with the rebate being of a depth to receive said insert, such that an end or tip or distal point of the second rim is substantially level or aligned with the face of the panel, or an intended level of a finished or decorated surface of the panel.

It is further contemplated that where a light fitting or fixture is described, said light fitting may be substituted with any other fitting or component to be installed into a panel, such as, speakers, furniture, ducts, piping, components of alarm or safety systems (e.g., smoke detectors, gas detectors, infrared motion detectors) or any other outlet, utility or appliance.

It is further contemplated that any such fittings or components or systems to be installed may be retrofitted with suitable adaptors for installing into a body or assembly as described in any one of the preceding aspects or embodiments.

It is further contemplated that an assembly may comprise the body as described herein, and in particular with reference to any one or more of the preceding aspects or embodiments.

The invention described herein provides for at least two separate rims, being of the same or different height projections of the first face of the body, where at least the first rim provides for a first reference height and the second rim provides for a second reference height. The reference heights being made with reference to the first face of the body or with reference to a face of a panel into which the insert is to be affixed or received.

In certain embodiments, the first rim is of a lower or smaller height or size then the second rim. In this manner, where for example a (curable) material such as a plaster is to be applied over the insert (for example to affixed of mechanically engage the insert with the panel to which it is to be affixed), a first application of a material can be made upon the insert, and an amount of material can be applied such that the material is applied to a thickness to align with the first rim. A second or subsequent layer of material may then be applied or coated, and this may be to a thickness to align with the second rim.

The insert component1can be formed in any manner. However preferred may be casting or moulding, such as injection moulding or extrusion moulding, depending on the shape of the body2and the other features which may be provided.

Various individual or combinations or compound materials may be used to form the insert component1. The material to use will depend on the specific application or use.

Examples of materials comprise one or more of: polymers such as PE, PP, PET, metals such as stainless steel, aluminium, and fibrous plasters such as compositions comprising gypsum, polymers, metals, compositions comprising fibrous reinforcement, including cementitious fibre reinforced materials, fibre-glass materials.

It will also be appreciated sections or parts or portions of the insert component1may be formed of a combination or materials.

Yet further, it may be desirable for the insert component1to achieve certain desired characteristics in terms of structural strength, fire or chemical resistance or ability to retard fire. For example, components or compounds may be included in the body or the body so formed to achieve: electrical conductivity, anti-static properties, electrically insulation, fire resistance or fire retarding capabilities, or even fire self-extinguishing properties.

Where reference in this specification is made to a “panel”, such a panel may include building panels, such as ceiling panels or wall panels. In certain typical applications, panel may be a building panel of fibrous plaster comprising gypsum.

As described above, material or medium or adhesive or other bonding or curable agents may be utilised to assist or provide for affixation or connection or engagement or inter-connection the insert component1and surfaces of the panel. In these situations, an adhesive may be pre-applied or provided upon the insert component1(such as upon the second face4). The adhesive or bonding agent may have a removal backing, such as a paper or sheet, which once removed exposes the adhesive or bonding agent for use.

In various embodiments, the adhesive or bonding agent may be curable by exposure to the surface which it is desired to come into contact with. Alternatively, another means may be used to facilitate curing—such as heat source, for example infra-red, or another energy source, for example ultra-sound, to excite the adhesive and set-off the curing process.

The materials or mediums or other agents can be passively or actively activated to cure and adhere to the panel so as to secure the insert component1in position.

A concealing step allows for application of a sufficient amount of the one or more materials as discussed above. Application of the material is performed by a user until the first or front face is made level with the face of the panel. Decoration or finishing materials can then be finally applied.

Sufficient amounts of material, such as plaster or similar materials, can be applied upon the insert component1and the building panel, then allowing the material, such as plaster to cure, and then polishing the material, such as sanding of plaster or similar material, to achieve a finished surface, optionally with a further final finishing material, such as a paint, applied.

Various tapes, such as a jointing tape, may be optionally applied about joint regions between the front face and the first face of the panel, although the present invention may allow a user to wholly negate the use of such an additional joint concealing material.

FIGS. 10 to 13illustrate an additional feature aspect for the insert, being a perimeter retention means to hold the insert in place in a rebate, however, the features as described above, alone or in combination, are interchangeable and compatible with the retention feature.

Referring toFIG. 10there is provided an insert component21to be affixed to, for example, a panel (P, seeFIG. 13). The insert component21comprises a body22. The body22includes a first face23and a second face24. The body21defines at least one opening25that extends between the first face23and the second face24. The at least one opening25is positioned within a perimeter26(such as an outer perimeter) of the body21.

In the illustrated form the perimeter is comprised of radially extending fingers to provide a broken circumference, however, this is merely a one possible form (e.g. implemented for material saving measures and greater surface area in contact with a curing material/adhesive) that may be, instead, an unbroken circular perimeter as shown inFIG. 1.

As above, the opening25may include a rim structure, e.g. first rim27provided upon the first face23and substantially about a perimeter of each opening25. A second rim28may be provided upon the first face23and substantially about the perimeter of each opening25, where the first rim27is located outwardly of the second rim28, relative to the perimeter of each opening25. Each of the first rim27and the second rim28are spaced from each other to define a channel region29therebetween. However, it is noteworthy that this feature is an independent aspect from the general concept of a perimeter retention means as will be hereinafter described.

To assist a user in holding the body22in place when inserted into a rebate, at least one perimeter retention means30is provided. In the illustrated form there are three such retention devices30spaced, preferably evenly, about the perimeter26. In the illustrated form the retention device/means is comprised of a resilient member31spanning between radially extending fingers such that, when a mid-point is depressed, it will flex inwardly (toward opening25) and bounce back outwardly (away from opening25).

Resilient member31preferably includes a protrusion32at the mid-point such that outward bias is directed through the protrusion32and onto any surface with which it is contacted. In the preferred usage situation, the surface in contact with perimeter protrusion32will be the edge/side wall of a rebate into which the body is inserted. This is generally illustrated byFIG. 13where a tapered/sharp edge33of protrusion32may bite into rebate wall R. Once held in place by the outward bias of one or more retention devices30a user can apply material M across the exposed first face23which will incorporate the body permanently into the panel/ceiling structure.

Alternative forms of biasing/resilient/retention device are possible without departing from the scope of the invention. For example, an outwardly biased member (31,32) may be mounted from a spring-loaded structure to generally provide the function of expanding the perimeter into engagement with a rebate wall or a sliding (biased or otherwise moveable radially outwardly) member (e.g. a spike) may extend into engagement with the rebate wall R.

Any of the disclosed insert components, such as insert component41shown inFIGS. 14 to 23, can provide for a member in the form of a body42, to which a fitting or fixture may be mounted to, or seated upon, and thereby supported. Such a member can be provided as a structural support for a fitting or fixture to be supported thereon or thereto.

The insert component41can also provide for a particular or pre-determined (i.e. a pre-formed) dimensioned or shaped opening45. Such an opening45providing the aperture for receipt therein of a fitting or fixture. Such a particularly dimensioned or shaped opening45provided by the insert component may facilitate the re-sizing or alteration in shape of an existing aperture in a panel, the insert component capable of receiving such a fitting of fixture. For example, the removal of traditional incandescent or halogen type light fittings and replacement by smaller format light fittings (e.g. LED lights) creates an issue of an overly large sized hole in a panel, with a smaller format light fitting to be replaced into that large(r) hole. As a consequence, a device which is capable of being provided in-situ into an existing aperture, yet which provides for a smaller (new) aperture to receive the new (smaller format) light fitting is advantageous. Similarly, in cases where retro-fitting of light is not needed, but instead in new builds or for new apertures being cut into panels, a device which provides for a suitable functionality to improve structural performance and reduce risks of break out in a friable panel (e.g. a plaster-type panel which may become compromised as to structural integrity about an aperture cut therein).

The insert component (as described herein) can be located or positioned into a rebate or recessed region of a panel, such that the insert component can be subsequently mechanically fixed into place, for example by application of one or more layers of material, such as a curable material like plaster or other curable medium or adhesives, or an adhesive tape, double sided tape, or by the use of fixing means or fasteners. In this manner, the insert component can be integrated or become more integrated into the panel. The insert component can then provide a particular structure for assisting with such an integration and as a support for a fixture of fitting.

For example, a contact or pressure sensitive adhesive may be provided on a second face of the insert (being the face which is to be put into contact with the panel), and may be revealed upon removal of a release or peel sheet. Alternatively, an adhesive may be provided which is heat cured or otherwise cures upon contact or placement when placed against the panel to which the insert is to be mounted or affixed.

This invention can also provide for a relatively uncomplicated system for reducing or altering the geometry, such as shape or size of an existing aperture, whilst at the same time provides a platform upon which materials, such as concealing compositions—e.g. plaster, paint or other fillers or finishes, may be applied to conceal the joint region between the insert component and the surrounding panel.

It will also be appreciated the present invention may be utilised for improving or strengthening the aperture or opening cut or made in a building panel to receive a fitting, such as a light fitting (or any other outlet or utility requiring an aperture through a building panel) or a wall socket (such as for electrical outlets or indeed any other outlet requiring an aperture through a building panel). For example, the existing aperture or opening referred to here may be the aperture which is initially cut or made in a building panel to then receive a fitting or fixture.

The insert component41of the invention may facilitate an improvement in the strength of the building panel around an aperture or opening through the panel and any finishes made about the aperture so cut or made, and in this way can help to minimise possible “break-out” in which the materials used around the aperture or opening are compromised as to their structural integrity due to forces imposed upon them, for example by a light fitting imparting a force on a building panel about the aperture. “Break out” may result in cracking of plaster or paint or other unsightly effects in decorative finishes around the aperture.

The insert component can facilitate the alteration in the shape or size of an aperture or opening through a panel, for example a building panel such as a ceiling or a wall.

The insert component41as described herein can advantageously provide for ease of installation to or on a panel. In an example, the insert41can be temporarily held in place with an adhesive, fastener, or tape, such as a double-sided tape, a pin, screw, or nail, or a projection (such as a spiked projection) formed on a flange47or second face44of the insert, to mechanically engage with a panel. In such an example, a curable adhesive m, such as a plaster, can be applied to the insert41to more permanently affix the insert, whilst the temporary attachment means can hold the insert in place during said curing.

In some examples, a second face44of the insert may comprise two portions51and52, with one portion51being a stepped or raised region. In an example, the stepped region may comprise a sidewall51A arranged to align the insert41to an aperture in a panel, and or retain the insert41in an aperture in a panel.

The insert41as described herein may provide for a panel surface mounted component which can be aligned with an aperture in a panel, whether the aperture is a pre-existing aperture (i.e. for resizing of an existing hole in a panel or other retro-fitting capabilities) or a new/fresh hole (i.e. for new builds, or new installations of fixtures into panels). The insert may also be used to fill an existing hole (i.e. for removing a fixture from a wall, and filling the existing hole).

The insert41as described herein may provide for a relatively low profile, and may include a tapered region from an outer perimeter46towards an inner portion, the insert being thinner in profile towards an outer perimeter46. In such an example, a plaster applied to said insert can taper to provide a more gradual change in surface on a panel. This may result in a reduced bulge appearance of the insert when installed in a panel.

The insert as described herein may be provided with a rim, such as rim48inFIG. 15, configured to act as a wall or edge to contain or align an adhesive material applied to the insert. Additionally, the channel49may also provide for a means to accept adhesive applied to the insert. Alone or in combination, the rim48and/or channel49may provide for a means of containing a curable adhesive applied to the insert, and as a guide when finishing the curable adhesive (for example, when sanding after curing) to provide a clean or neat appearance to an edge of the curable adhesive surrounding the aperture of the insert41.

FIGS. 14 to 23illustrate an example embodiment of an insert.FIGS. 14 and 15shown perspective views of a second face44and a first face43of the insert41.

The insert41ofFIGS. 14 to 23can be affixed to a panel, and comprises a body42, the body comprising a first face43and a second face44. The body42defines at least one opening45extending between the first face43and the second face44, said at least one opening45positioned within a perimeter46of the body42. A flange portion47is located substantially radially outwardly from one or each of said at least one opening45.

At least one rim48is provided upon said first face and substantially about a perimeter of each said opening45. At least one channel region49is provided in said first face43, and substantially about the perimeter of each said opening45, said channel region49located outwardly of said rim48relative to said perimeter of each said opening45.

In an alternative embodiment, there is provided an insert component41to be affixed to a panel, said insert component comprising a body42, the body42including a first face43and a second face44, and the body42defining at least one opening45extending between the first face43and the second face44, said at least one opening45positioned within a perimeter46of the body42. A flange portion47is located substantially radially outwardly from one or each of said at least one opening45. At least one rim48is provided upon said first face43and substantially about a perimeter of each said opening45. The flange portion47has a relatively greater wall thickness in a region adjacent to or at said rim48, and is of a relatively reduced wall thickness in a region adjacent to or at said perimeter46of said body42.

As shown inFIGS. 16 and 19, the rim48may be a projection extending upwardly or in a direction away from said first face43and said second face44, such that the rim48may be provided as a projection upstanding from said first face43.

A height of the rim48may be about 2 mm, or about 3 mm, or about 4 mm, or about 5 mm, or about 6 mm, or about 7 mm, or about 8 mm, or about 9 mm, or about 10 mm, or about 11 mm, or about 12 mm, or may be less than about 12 mm, or less than about 10 mm, or less than about 8 mm, or less than about 6 mm, or less than about 4 mm, or less than about 2 mm, as measured from said first face43of said body42.

As shown inFIG. 19, the channel49may be provided as a recess in said first face43, and may be located between the rim48and said flange portion47. The rim48may form a first channel wall49A of said channel. A height of said first channel wall49A may be substantially equal to or greater than a second channel wall49B, and the second channel wall49B may be located outwardly of said first channel wall49A relative to said perimeter of each said opening. The second channel wall49B may be located at an inner edge of the flange47.

The channel region49may have a floor or base49C defining a channel region depth, said floor or base49C being of a level, or providing for floor or base sections of a level substantially lower than said first face43of said body42or said flange portion47.

A depth of the channel49may be about 1 mm, or about 2 mm, or about 3 mm, or about 4 mm, or about 5 mm, or about 6 mm, or about 7 mm, or about 8 mm, or about 9 mm, or about 10 mm, or may be less than about 10 mm, or less than about 8 mm, or less than about 6 mm, or less than about 4 mm, or less than about 2 mm, as measured from said first face43of said body42.

The channel49may be of a pre-determined width, said width defined between said first channel wall49A and said second channel wall49B.

As shown inFIG. 20, the width and/or said depth of said channel49may be sufficient to accommodate or receive a (curable) material M.

The width of the channel49may be greater than about 1 mm, or greater than about 2 mm, or greater than about 3 mm, or greater than about 4 mm, or greater than about 5 mm, or greater than about 10 mm, or greater than about 15 mm, or is about 2 mm, or is about 3 mm, or is about 4 mm, or is about 5 mm, or is about 6 mm, or is about 8 mm, or is about 10 mm, or is less than 10 mm.

The material M may be a filler material (such as, but not limited to, one or more of: a plaster-type or render-type material, such as a material comprising of gypsum, lime or cement material, or is a material capable of being decorated or may be a material which can be finished, e.g. can be sanded to a finished surface, for a subsequent application of a decorative material, such as paint).

One or more of said at least one opening45may further comprise of a ledge50, said ledge50providing a support surface extending substantially inwardly toward a centre of said opening45. The support surface may be a surface facing the same direction as said first face43of said body42. The support surface may be a substantially planar surface, or alternatively the support surface may comprise a channel or recess. The planar surface, channel, or recess may be provided to receive a fitting or fixture as described herein. Additionally, the channel or recess of the support surface may be provided to reduce material thickness during a forming process of the insert. The support surface of said ledge50may be recessed from said rim48, or may be of a reduced height relative to said rim48. The support surface may provide a surface upon which an item is seatable, such as a light fixture or fitting, or a smoke alarm or smoke detector, or speaker, or other fittings or fixtures or devices.

The second face44may comprise an inner portion51and an outer portion52. The outer portion52may substantially correspond with said flange portion47, and the inner portion51may substantially correspond with said channel49and said rim48.

The inner portion51may be a raised or stepped region, raised or stepped in a direction to accommodate said channel49.

A sidewall51A may define a step between said outer portion52and said inner portion51, and may be provided as a guide for locating said body into an aperture of a panel.

The outer portion52may be substantially planar, or may comprise one or more projections, such as projections53inFIGS. 22 and 23, the one or more projections being of a bevelled, tapered and/or of a spiked form.

As shown inFIG. 20, the outer portion52may be adhered or affixed to a surface of a panel P. In one example embodiment, the one or more projections53, as shown inFIGS. 22 and 23, may extend in a direction away from said second face44, or in a direction toward a surface of a panel to which said insert41is to be affixed. The one or more projections53may provide for a mechanical engagement or attachment with the panel, and may be provided as an array about the second face44of said outer portion52. The one or more projections53may provide for a temporary, or initial, or additional engagement with a panel, in combination with a curable material applied to the insert to further adhere the insert41to the panel. Whilst four projections53have been illustrated inFIG. 22, it will be understood that any number of projections may be spaced or provided in arrays on the insert41to provide the described initial engagement with a panel.

As for example shown inFIG. 20, an insert component41can be positioned partially into a rebated region R a panel P. The insert component41can then be mechanically affixed in place, for example by application of one or more layers of material or medium M. In an example embodiment, a first layer of material M1may be applied, which may include using a sidewall of rim48as a tool guide. This layer of material may fill channel49, which is partially recessed into the rebated region R of panel P. The apertures49D of channel49may allow for excess of first material M1to escape the channel into the space behind the insert, which may avoid the formation of air pockets within the channel. This can also provide for a greater volume of material M1to be applied and received by the insert to assist with a greater volume of the material M1which can ultimately be cured in place to connect with the insert.

The first material M1may also provide for a first layer of adhesion for adhering the flange region47to the panel P, which may include material M1passing through flange apertures47A to adhere onto a surface of panel P. The first material M1may adhere the insert41to the panel P, and may add strength to the panel and/or insert surrounding a fixture to be fitted. Put another way, the first material M1may bridge or facilitate strengthening of the connection joint made between the insert41and the panel P.

Desirably, providing a system for strengthening the joint made between the insert and the panel may provide for a system which is capable of receiving larger or heavier items, yet avoiding or minimising the risks of break out. That is, the insert of the present disclosure may provide for an increased load factor capability relative to a traditional re-sizing of a hole which does not use the insert of this invention.

A second or finishing layer of material M2may also be applied to the insert, which may include using the face or top of rim48as a tool guide. This may allow the second or finishing material M2to be applied substantially level with the face of rim48, whilst covering flange47and channel49. Such a configuration may provide for a finished or finishable (e.g. by sanding and/or painting) surface.

In one preferred mode of installation, as shown inFIG. 20, the insert component41is to be positioned within a rebated region R of a panel surface P. The rebate R being of sufficient depth to at least partially accommodate the insert component41, for example to accommodate the second portion of the second face44. Put another way, the rebate R may be of a depth such that the second portion of the second face44is substantially within the rebate, whilst the ledge50is substantially in-line with the surface of the panel into which the insert component41is to be received. That is, a rebate can be formed in a face of a panel, with the rebate being of a depth to partially receive said insert, such that the flange portion47rests on the surface of the panel.

The flange portion47may have a relatively greater wall thickness in the region adjacent to or at said channel49, and may be of a relatively reduced wall thickness in a region adjacent to or at said perimeter46of said body42. In an example, the flange portion47may be of a wall thickness of about 0.5 mm in a region adjacent to or at said perimeter46of said body42, and the flange portion47may be of a wall thickness of about 1 mm in a region adjacent to or at said channel49. The flange portion47may be substantially tapered in a reducing wall thickness, said wall thickness reducing in a direction as said flange portion47extends substantially radially outwardly from said channel49. It will be understood that the abovementioned flange portion thickness is exemplary, and the invention should be considered to incorporate any suitable flange portion thickness producing a tapered, curved, and/or angled profile.

As shown inFIG. 21, the first face43may comprise said rim48defining a first projected height H1, said flange portion47at or substantially adjacent to said channel49defining a second projected height H2, and said flange portion at or substantially adjacent to said perimeter46defining a third projected height H3. Each of said first H1, second H2and third H3projected heights may be in reference to the second face44, or a side of the flange portion47on the second face44, which may be substantially planar as illustrated inFIG. 21.

Put another way, the rim48may define a first projected height H1of said first face43, said flange portion47at or substantially adjacent to said channel49may define a second projected height H2of said first face43, and said flange portion47at or substantially adjacent to said perimeter46may define a third projected height H3of said first face43.

The third projected height H3may be less than said second projected height H2, and the first projected height H1. Similarly, the second projected height H2may be less than said first projected height H1. This may result in a configuration where the flange portion47may slope from said second projected height H2to said third projected height H3.

The first face43may further comprise said support surface of said ledge50defining a fourth projected height (indicated as H4), and the fourth projected height may be the same, or advantageously may be less than said first projected height, or matches the height of the first projected height. In an example embodiment, the support surface of said ledge50may be at substantially the same height as the second face44, or a side of the flange portion47on the second face44. In such a configuration, when the insert is installed with the second face44(or the side of the flange portion47on the second face44) substantially parallel and abutted to the panel surface, the support surface of the ledge50may be at substantially the same height and/or level as the surface of the panel P. Alternatively, the support surface of the ledge50may be positioned to as to be above or below the surface level of the panel surface or of the second face44, or a side of the flange portion47on the second face44. This may facilitate a fixture or fitting installed in the insert to be placed at a level corresponding with the panel surface P, or may be recessed from the panel surface or may project slightly beyond the panel surface as desired by aesthetics of installation.

The fourth projected height H4may be a zero, or a positive or a negative height value with respect to the reference plane defined by the second face of the flange portion47. That is, the support surface of the ledge50may be provided so as to provide for a greater height of recess relative to the projected height of the rim (being the first projected height) or may be of a smaller projected height, or may be of the same projected height as the first projected height H1of the rim48.

An outer edge of said flange portion47may define said perimeter46of said body42, and the first face43of said outer edge may comprise a chamfered edge portion as illustrated inFIG. 21.

The flange portion47may extend substantially radially outwardly of said channel49, and may extend substantially about a part, or parts, or substantially an entirety, of said perimeter46of said body42. The flange portion47may extend continuously radially outwardly of said channel49, or alternatively the flange portion47may extend as two opposing sides of said body42(i.e. is cut-off sides, as a radially discontinuous flange portion).

The flange portion47may comprise one or more apertures47A, said apertures47A extending through said body42. The apertures47A may provide for a void through said body42, and may be distributed about said flange portion47.

The channel49may comprise one or more channel apertures49D, and said apertures49D may extend through said body42. The channel apertures49D may provide for a void through said body42, and may be distributed about said channel49.

The channel49may comprise one or more ribs49E, and the one or more ribs49E may extend across said channel49. The one or more ribs49E may be strengthening members, and may provide for a strengthening structure between a wall of said rim48(for example channel sidewall49A) and a wall of said flange portion47(for example channel sidewall49B). The one or more ribs49E may extend substantially across said channel49or said floor of said channel49, or between sidewalls49A/B of said channel49. The one or more ribs49E may be distributed about said channel49.

The one or more ribs49E may be of a height below the first face43, or said one or more ribs49E may be provided of a height recessed from said first face43, and/or of said flange portion47. In an example, the ribs49E are provided as recessed ribs so as to not protrude through a curable material that may be applied to insert41.

The body42may be substantially circular, oval or of a rectilinear perimeter shape. Additionally, one or more of said at least one opening(s)45in said body42may be substantially circular, oval or of a rectilinear perimeter shape, and the ledge50may be substantially circular, oval or of a rectilinear perimeter shape.

A diameter of an inner perimeter of said rim48may be about 25 mm to about 104 mm, or is about 76 mm, or about 86 mm, or about 102 mm, or about 103 mm, or about 104 mm, or about 105 mm, or about 106 mm, or may be about 160 mm, or may be about 200 mm, or is greater than about 10 mm, or greater than about 20 mm, or greater than about 25 mm, or greater than about 30 mm, or greater than about 35 mm, or greater than about 40 mm, or greater than about 50 mm, or greater than about 85 mm, or greater than about 100 mm, or greater than about 105 mm, or greater than about 125 mm, or greater than about 150 mm, or greater than about 175 mm, or greater than about 200 mm, or greater than about 300 mm, or greater than about 400 mm.

The flange47may be detachable or attachable or integral with said body42. Additionally, the rim48or the channel49, or both, may be detachable or attachable or integral with said body42, and the ledge50may be detachable or attachable or integral with said body42.

A separate component piece, such as a plate-type component piece as described in relation toFIG. 9, may be provided for seating upon the ledge50. The separate component piece may be provided as a plate-type component piece comprising of one or more apertures. The separate component piece may be provided as a plug or cap for the insert component, and may be substantially planar and of a substantially constant thickness. The plate-type component piece may be provided to fill an unwanted hole in a panel, and may be arranged to receive a curable material as described herein.

As described herein, the insert41as defined in any of the embodiments disclosed herein may be affixed to a face of a panel. A rebate may be formed in said face of said panel, said rebate being of a depth to receive said insert41, such that an end of said rim48is substantially level or aligned with said face of said panel, or an intended level of a finished or decorated surface of said panel.

A structure may be formed in-situ with a panel, and said insert41as defined in any of the embodiments disclosed herein may be affixed to a face of the panel, and a rebate may be formed in said face of said panel and sized so as to receive the insert such that the at least a portion at the perimeter of the body42is configured to extend to engage a side of the rebate and retain the insert therewithin the rebate. For example, the side wall51A of the stepped region of the second face44may substantially engage with a side of the rebate, and the flange portion47may substantially overlap a face of the panel.

The insert as described above in relation toFIGS. 14 to 20may be combined with any or all additional features described above. For example, the insert of the invention may further include projections or bumps on the rebate-facing face of the body so as to provide a spacing function of the body from the rebate inner surface and allow flow of adhesive and/or curable material such as plaster. Additionally, the insert may comprise one or more resilient elements or members, such as resilient member31inFIG. 10, arranged on a perimeter46of the body42, and/or the sidewall51A of the second face44.

The foregoing description of the invention includes preferred forms thereof. Modifications may be made thereto without departing from the scope of the invention.