A letterplate assembly

Abstract

A letterplate assembly 10 for a door comprising internal and external subassemblies, together defining a connecting slot 12. The internal section has an inner body 11 defines a first portion of the connecting slot, an internal surround 13 attached to the inner body and mounting an internal flap 14 to the body; the external section has an external body 18 defining a downwardly angled section portion of the connecting channel, and an external surround 10 connected to the body and mounting an external flap 20 to the body. The internal flap has at least one extension 15 with a slot opening (16, fig 4) therein. A projection 17 extends from the internal surround into the slot opening, which may limit the opening angle of the internal flap. A pair of connecting fasteners 21 mounted between the external surround frame and the internal frame to clamp the subassemblies together.

Description

Technical Field of the Invention The present invention relates generally to the field of letterplates which is a common name for an assembly which defines a slot through an external door of a building for delivery of postal items. Background to the Invention As discussed in UK Patent Applicatiopn No. 2521449, the external door of a building may be provided with a slot for delivery of postal items etc. It is common to provide a letterplate to cover the slot for aesthetic reasons, for draught exclusion and the like, but it has been found that the provision of the slot can create a security risk. Since commencing use of the letterplates, arrangements have been developed to address the security risks. These arrangements may not be aesthetically pleasing, may be difficult or expensive to manufacture and / or install. The Door &Hardware Federation Technical Specification DHF TS 008:2022 defines the requirements for classification of enhanced security and general requirements for letter plate assemblies and slide through boxes as defined below: • letter plate assemblies that allow mail to pass directly through a door or side panel; • slide through boxes that allow mail to pass directly through a door or door side panel and which are designed for fire and / or non-fire applications. This technical specification is applicable to letter plates and slide through boxes intended for installation in doors and door side panels of any materials and, in specific cases, doors and side panels of particular materials. The technical specification also prescribes a durability test as well as a variety of security tests including a mail retrieval test, a manipulation test and a fishing test and a number of arson tests. In addition to the tests prescribed by the Door &Hardware Federation Technical Specification DHF TS 008:2022, a letterplate assembly should also meet the Fire and Smoke test (ENI634) which replicates real life fire risk. It is therefore an object of this invention to provide a letterplate assembly which meets the tests prescribed by the Door &Hardware Federation Technical Specification DHF TS 008:2022, and the Fire and Smoke test (ENI634), or overcomes or ameliorates at least one of the issues described above. Summary of the Invention According to a first aspect there is a provided a letterplate assembly for a door or side panel, the letterplate assembly comprising: a. an internal subassembly configured to be fitted on an internal side of the door and comprising: i. an internal body defining a first portion of a connecting slot; ii. an internal surround attached to the internal body and mounting an internal flap thereto, the internal flap comprising at least one extension with a slot opening therein, iii. a projection extending from the internal surround at least into the slot opening; b. an external subassembly configured to be fitted on an external side of the door and comprising: i. an external body defining a downwardly angled second portion of the connecting slot aligned with the first portion of the connecting slot; ii. an external surround attached to the external body and mounting an external flap thereto; and c. at least a pair of connecting fasteners mounted between the internal surround and the external surround to clamp the internal subassembly relative to the external subassembly. Providing a letterplate assembly with the projection extending from the internal surround at least into the slot opening in the extension of the internal flap functions to limit the opening angle of the internal flap. Together with the downwardly angled second portion of the connecting slot, this can assist with defeating at least the mail retrieval test, a manipulation test and fishing test, increasing the security of the letterplate assembly. The letterplate assembly may be provided for a door or side panel. The features of the letterplate assembly are preferably the same for a door or a side panel. Preferably, the door or side panel has an opening cut into it and the internal subassembly an external subassembly of the letter plate assembly are fitted to the door or side panel through the opening and a sandwiched to the door or side panel. In a preferred form, the letter plate assembly is clamped to the door side panel through the opening. The at least one connecting fastener may preferably be provided within the footprint of the opening in the door, or within the footprint of the internal body, and / or external body, preferably the in-door portion of the internal body (the preferred in-door portion of the external body preferably fits within the in-door portion of the internal body). In other words, separate openings for the at least one connecting fastener are not required with the letter plate assembly of a preferred embodiment. Providing the at least one connecting fastener within the footprint of the opening in the door side panel means that separate openings for the connecting fastener are not required as these may weaken the door side panel. The letter plate assembly may comprise an internal subassembly configured to be fitted on an internal side of the door or side panel, the internal subassembly comprising an internal body defining a first portion of a connecting slot. In a preferred embodiment, the internal surround may be attached to the internal body and then the internal body may be mounted to an internal side of the door or side panel. Preferably, the internal surround may be attached to the internal body using at least one, and preferably a plurality of fasteners extending through the internal body from the reverse side thereof and at least into the internal surround. The internal body may include an in-door portion, which may be located within the thickness of the door side panel when the letter plate assembly is fitted thereto. In one form, the in-door portion may be shaped. The in-door portion may have a planar upper and lower surface. The internal body may include a flange extending radially outwardly from the in-door portion. The flange may be substantially rectangular. The flange may be substantially planar. The internal body may be fitted relative to the door or side panel so that at least a portion of a reverse surface of the flange may abut the surface of the door about the opening. At least one, and preferably a pair of clamping openings may extend through the flange. Each of the clamping openings may be provided with a seat, the seat may preferably be annular surrounding a depression. In use, the seat may receive a portion of a connector bolt body thereinto. At least one, and preferably a plurality of mounting openings may be provided in the flange to allow the internal surround to be connected to the flange. Preferably two or more mounting openings are provided and in a particular preferred embodiment, four mounting openings may be provided. A shaped groove or slot may be provided in the flange to at least partially seat the projection extending from the internal surround. The shaped groove or slot may extend from a lateral side edge toward the centre of the flange. The groove or slot may be open at an obverse side thereof. The groove or slot may be partially threaded. A shaped groove or slot may be provided on both lateral sides of the flange, each extending toward the centre of the flange. The in-door portion of the internal body may include a main connecting slot box and a pair of side mount parts, one side mount part on either lateral side of the main connecting slot box. The main connecting slot box and pair of side mount parts preferably extend from the reverse face of the internal body. The main connecting slot box is preferably defined by a number of walls, preferably an upper wall, along wall and a pair of end walls to define a box around the first portion of the main connecting slot in the internal body. The dimensions of the main connecting slot box may preferably be such that it is closely received within the opening in the door or side panel in order to locate the letter plate assembly in the door side panel. Each of the side mount parts are preferably spaced from the respective preferred end wall of the main connecting slot box. Each of the side mount parts may preferably have at least one arcuate outer end wall closer to the lateral edge of the internal body. A receiving opening may be provided between the end walls of the main connecting slot box and the side mount part on either lateral end of the internal body. The receiving opening may preferably receive the at least one extension provided on the internal flap when the internal flap is in the closed position. The receiving opening may be a slot opening. The receiving opening is preferably oriented substantially vertically. The receiving openings are preferably separated from the first portion of the connecting slot. The receiving openings may preferably guide movement of the at least one extension provided on the internal flap during movement of the internal flap. A guide opening may be provided through each of the side mount parts. The guide opening provided through each of the side mount parts may align with a respective clamping opening provided in the internal surround. The guide opening may extend to the flange of the internal body at the obverse side. The guide opening may guide or locate the connector bolt body. The letter plate assembly may comprise an internal subassembly configured to be fitted on an internal side of the door, the internal subassembly comprising an internal surround attached to the internal body and mounting an internal flap thereto, the internal flap comprising at least one extension with a slot opening therein. The internal surround may preferably have a substantially planar configuration. In an embodiment, the internal surround may have a substantially C-shaped obverse wall when viewed in cross-section with a pair of end walls to define a hollow volume in a reverse side of the internal surround into which (the flange of) the internal body is received when the internal subassembly is assembled. At least one, and preferably a pair of mounting openings are provided through the internal surround, preferably the obverse wall thereof, each for one of the pair of connecting fasteners. Each of the mounting openings may be provided with an annular seat on a reverse side of the internal surround. The annular seat will preferably define a depression or opening into which an end of a preferred connector bolt body is seated when the letter plate assembly is assembled. The letterplate assembly of the invention can be used in relation to doors or side panels of different thicknesses through the provision of different length connector bolt bodies to suit the door or side panel thickness. The connector bolt body is preferably seated in a seat on the reverse side of the external surround at one end and a seat on the reverse side of the internal surround at the opposite end. The internal surround preferably has a central opening which is aligned with the main connecting slot through the letter plate assembly. A slot opening is preferably provided spaced from each lateral end of the central opening of the internal surround, and through which a respective at least one extension of the internal flap will extend. Each of the slot openings is preferably substantially vertical. The internal surround may include a corresponding number of receiver ports to receive fasteners therein to mount the internal body to the reverse side of the internal surround. Preferably, the receiver ports extend into, but not through the internal surround. An elongate slot opening may be provided at an upper side of the internal surround on the obverse face to receive and seat a hinge tube of the internal flap. A transverse opening may be provided at each end of the elongate slot opening into which a hinge pin may mount or fix in order to fix the hinge tube of the internal flap relative to the internal surround. At least one, and preferably both end walls of the internal surround may include a transverse opening extending through the respective end wall to receive a projection extending into the slot opening provided on the respective at least one extension of the internal flap. The projection is preferably mounted to the end wall of the internal surround. The projection will preferably extend through the end wall of the internal surround and at least a portion of the projection extend into or through the slot opening provided on the respective at least one extension of the internal flap The transverse opening in the end wall may be at least partially internally threaded. In one embodiment, a larger diameter outer portion is provided, and a smaller diameter inner portion is provided. The larger diameter outer portion may be internally threaded. The smaller diameter portion may be unthreaded. The projection may be correspondingly configured and threaded. The projection may include an outer head end. The outer head end may be provided with shaped engagement portion to engage with a tool. The projection may extend through the end wall of the internal surround, be seated against an obverse face of the internal body via the groove or slot, and extend into or through the slot opening provided on the respective at least one extension of the internal flap. This may support the projection over its length against an adjacent surface, greatly increasing the resistance of the projection to being displaced, unless it is removed laterally. As mentioned above, preferably a projection will be provided at both lateral ends of the internal surround to limit the opening angle of the internal flap on both lateral ends of the internal flap. The transverse openings will preferably extend from a lateral edge of the internal surround toward the main connecting slot to intersect with the slot opening provided on the respective at least one extension of the internal flap. The internal flap may preferably have a unitary or single piece construction. The internal flap is preferably provided with an aesthetic appearance. The internal flap may have a main flap portion which is arcuate from top to bottom. An abutment edge may be provided along the bottom edge of the internal flap in order to abut the obverse face of the internal surround when the internal flap is closed. A hinge tube may be provided at an upper side of the internal flap. The hinge tube may extend over a bulk of the length of the top of the flap. The hinge tube is preferably hollow. In use, the hinge tube may receive a hinge rod. The hinge rod may preferably mount the hinge tube relative to the preferred slot opening provided in the obverse surface of the internal surround and allow the internal flap to pivot or rotate about the hinge rod. The hinge rod may have at least one spring-loaded end portion to allow a hinge rod, and the internal flap to be removed from the internal surround. Alternatively, one or more fasteners may be provided to mount the hinge rod and / or internal flap relative to the internal surround. As mentioned above, at least one, and preferably a pair of extensions extend from a reverse side of the internal flap. The extensions may be referred to as gussets. Preferably, an extension will be provided adjacent to, but spaced from both lateral ends of the internal flap. The extensions will preferably extend substantially vertically. The extensions will preferably extend substantially perpendicularly from the reverse surface of the internal flap. Each of the extensions may preferably be planar. The extensions may be provided with an arcuate lower edge. The slot opening is preferably provided through each of the extensions. In one form, the slot opening is arcuate to allow the pivot or rotation of the internal flap between the closed end open positions. The length of the arcuate slot opening may preferably define the opening angle possible of the internal flap. At each end of the opening or closing movement of the internal flap, the respective projection associated with the internal surround will preferably abut the respective end of the slot opening. The internal flap will preferably move from a position in which it is substantially vertical in the closed position to a fully open position. Preferably, the slot opening is provided so that the internal flap has an opening of between 30° and 40° when fully open, more preferably between 35° and 40° when fully open and most preferably approximately 37.5° when fully open. The letterplate assembly preferably comprises an external subassembly configured to be fitted on an external side of the door or side panel, the external subassembly comprising an external body defining a second portion of a connecting slot. In a preferred embodiment, the external surround may be attached to the external body and then the external body may be mounted to an external side of the door or side panel. Preferably, the external surround may be attached to the internal body using at least one, and preferably a plurality of fasteners extending through the external body from the reverse side thereof and at least into the external surround. The external body may include an in-door portion, which may be located within the thickness of the door or side panel when the letter plate assembly is fitted thereto. In one form, the in-door portion may be shaped. The in-door portion may have a planar upper and lower surface to be received within the first portion of the main connecting slot in the internal body. The downwardly angled shape may be defined internally through the in-door portion of the external body. The external body may include a flange extending radially outwardly from the in-door portion. The flange may be substantially rectangular. The flange may be substantially planar. The external body may be fitted relative to the door or side panel so that at least a portion of a reverse surface of the flange may abut the surface of the door about the opening. At least one, and preferably a pair of clamping openings may extend through the flange. Each of the clamping openings may be provided with a seat, the seat may preferably be annular surrounding a depression. In use, the seat may receive a portion of a connector bolt body thereinto At least one, and preferably a plurality of mounting openings may be provided in the flange to allow the external surround to be connected to the flange. Preferably two or more mounting openings are provided and in a particular preferred embodiment, four mounting openings may be provided. A reinforcing member may be provided adjacent to the reverse side of the external body. The reinforcing member may extend below the in-door portion of the external body. In one form, the reinforcing member may be a bar or similar. The Bar may be planar and rectangular. The reinforcing member may be mounted to the reverse face of the external body using fasteners from the reverse side of the external body so that the fasteners are not accessible if the external surround is removed from the external body. The in-door portion with the downwardly angled second portion of the connecting slot is preferably aligned with the first portion of the connecting slot during assembly of the letterplate assembly. Preferably, the in-door portion of the external body is received within the in-door portion of the internal body. The letterplate assembly preferably comprises an external subassembly configured to be fitted on an external side of the door or side panel, the external subassembly comprising an external surround attached to the external body and mounting an external flap thereto. The external surround may preferably have a substantially planar configuration. In an embodiment, the external surround may have a substantially C-shaped obverse wall when viewed in cross-section with a pair of end walls to define a hollow volume in a reverse side of the external surround into which the flange of the external body is received when the external subassembly is assembled. At least one, and preferably a pair of mounting openings are provided into the external surround, preferably the obverse wall thereof, each for one of the pair of connecting fasteners. Each of the mounting openings may be provided with an annular seat on a reverse side of the external surround. The annular seat will preferably define a depression or opening into which an end of a preferred connector bolt body is seated when the letter plate assembly is assembled. In the external surround, the mounting openings are preferably ‘blind’ openings, extending into the reverse side of the external surround, but not through. The external surround preferably has a central opening which is aligned with the main connecting slot through the letter plate assembly. The external surround may include a corresponding number of receiver ports to receive fasteners therein to mount the external body to the reverse side of the external surround. Preferably, the receiver ports extend into but not through the external surround. An elongate slot opening may be provided at an upper side of the external surround on the obverse face to receive and seat a hinge tube of the external flap. A transverse opening may be provided at each end of the elongate slot opening into which a hinge pin may mount or fix in order to fix the hinge tube of the external flap relative to the external surround. There are preferably no openings on an obverse side of the external surround except the central opening. The external flap may preferably have a unitary or single piece construction. The external flap is preferably provided with an aesthetic appearance. The external flap may have a main flap portion which is arcuate from top to bottom. An abutment edge may be provided along the bottom edge of the external flap in order to abut the obverse face of the external surround when the external flap is closed. A hinge tube may be provided at an upper side of the external flap. The hinge tube may extend over a bulk of the length of the top of the flap. The hinge tube is preferably hollow. In use, the hinge tube may receive a hinge rod. The hinge rod may preferably mount the hinge tube relative to the preferred slot opening provided in the obverse surface of the external surround and allow the internal flap to pivot or rotate about the hinge rod. The hinge rod may have at least one spring-loaded end portion to allow a hinge rod, and the internal flap to be removed from the external surround from the reverse side. Alternatively, one or more fasteners may be provided to mount the hinge rod and / or external flap relative to the external surround. The letterplate assembly preferably comprises at least a pair of connecting fasteners mounted between the internal surround and the external surround to clamp the internal subassembly relative to the external subassembly. Each connecting fastener may be a multipart fastener. In one form, each connecting fastener may comprise two parts, namely a connector bolt body and an elongate threaded connector bolt. The preferred connector bolt body may be mounted to a reverse face of the external surround. The connector bolt body may be permanently mounted to the external surround. The connector bolt body is preferably provided with an internally threaded bore. The internally threaded bore may be provided with sections of different dimension. The connector bolt body preferably extends from the external surround toward the internal surround. The connector bolt body preferably extends through the guide openings in the side mount parts of the internal body. The connector bolt body may preferably be located within the seats provided in a reverse face of the internal support. The threaded connector bolt is preferably inserted from the obverse side of the internal support to engage with the connector bolt body and clamp the external support, the external body, the internal body and the internal support together through the main opening in the door or side panel so that the respective flanges of the internal body and external body and the external support and internal support abut opposite sides of the door or side panel. The openings in the obverse side of the internal support will be covered by the side portions of the internal flap which are located laterally outside the extensions. A gasket may be provided between the reverse face of the external body flange and the door or side panel to seal to the external side of the door orside panel. The in-door parts of the internal body and external body and the side mount parts may be surrounded by an annular, intumescent band to provide fire resistance to the letter plate assembly. As mentioned above, the letter plate assembly is preferably fitted to the door or side panel through a single cutout opening in the door or side panel. A single tool is preferably used to form the cutout in a single pass. The pair of connecting fasteners are preferably located inside the cutout opening. When fitted to the door or side panel, the periphery of opening in the door or side panel will preferably be covered by the respective flanges of the internal body and external body and the internal and external supports. Detailed Description of the Invention In order that the invention may be more clearly understood one or more embodiments thereof will now be described, by way of example only, with reference to the accompanying drawings, of which: Figure 1 is an axonometric view of a letterplate assembly according to an embodiment. Figure 2 is an exploded view of the configuration illustrated in Figure 1. Figure 3 is an axonometric view of an internal body of the configuration illustrated in Figure 2. Figure 4 is an elevation view of an obverse face of the internal body illustrated in Figure 3. Figure 5 is an end elevation view of the internal body illustrated in Figure 3. Figure 6 is a section view of the internal body illustrated in Figure 4 along line E-E. Figure 7 is an elevation view of an obverse face of the internal surround illustrated in Figure 3. Figure 8 is an elevation view of a reverse face of the internal surround illustrated in Figure 7. Figure 9 is an end elevation view of the internal surround illustrated in Figure 7. Figure 10 is a section view of the internal surround illustrated in Figure 9 along line J-J. Figure 11 is a section view of the internal surround illustrated in Figure 7 along line G-G. Figure 12 is a section view of the internal surround illustrated in Figure 8 along line I-I. Figure 13 is an axonometric view of a limit pin from the embodiment illustrated in Figure 2. Figure 14 is an axonometric view of the internal flap from the embodiment illustrated in Figure 2. Figure 15 is an end elevation view of the internal flap illustrated in Figure 14. Figure 16 is an axonometric view of the external body of the configuration illustrated in Figure 2. Figure 17 is an end elevation view of the external body illustrated in Figure 16. Figure 18 is a section view through the centre of the external body illustrated in Figure 16. Figure 19 is an elevation view of an obverse face of the external body illustrated in Figure 16. Figure 20 is an elevation view of a reverse face of the external body illustrated in Figure 16. Figure 21 is an axonometric view of the external surround illustrated in Figure 2. Figure 22 is an elevation view of the reverse face of the external surround illustrated in Figure 21. Figure 23 is a section view of the external surround illustrated in Figure 22 along line C-C. Figure 24 is an axonometric view of the external flap illustrated in Figure 2. Figure 25 is an axonometric view of a bolt body of an embodiment. Figure 26 is an elevation view of the reverse face of the internal body with the door cutout superimposed thereon. A letterplate assembly 10 of a preferred embodiment is illustrated in the accompanying Figures. The letterplate assembly 10 may be used for a door or a side panel as the features of the letterplate assembly will be similar whether installed in a door or a side panel. The illustrated letterplate assembly 10 comprises an internal subassembly configured to be fitted on an internal side of the door, and an external subassembly configured to be fitted on an external side of the door. The internal subassembly comprises an internal body 11 defining a first portion of a main connecting slot 12, an internal surround 13 attached to the internal body 11 and mounting an internal flap 14 thereto. The internal flap 14 has a pair of extensions 15 with a slot opening 16 therein. A projection pin 17 extends from the internal surround 13 extends into the slot openings 16 to limit the opening angle of the internal flap 14. The external subassembly comprises an external body 18 defining a downwardly angled second portion of the main connecting slot 12 aligned with the first portion of the main connecting slot and an external surround 19 attached to the external body 18 and mounting an external flap 20 thereto. A pair of connecting fasteners 21 are mounted between the internal surround 13 and the external surround 19 to clamp the internal subassembly relative to the external subassembly through the door or side panel. As shown in Figure 26, the door or side panel has an opening 22 cut into it (hashed portion) and the internal subassembly and external subassembly of the letter plate assembly 10 are fitted to the door or side panel through the opening 22, and a sandwiched to the door or side panel. In a preferred form, the letter plate assembly 10 is clamped to the door or side panel through the opening 22. As shown in Figure 26, the connecting fasteners 21 (illustrated in a preferred form of connector bolt 23 and connecter bolt body 24) are provided within the footprint of the opening 22 in the door. In other words, separate openings for the connecting fasteners 21 are not required with the letter plate assembly 10. In the illustrated embodiment, the internal surround 13 is attached to the internal body 11 and then the internal body 11 is mounted to an internal side of the door or side panel. The internal surround 13 is attached to the internal body 11 using a plurality of fasteners extending through mounting openings 27 the internal body 11 from the reverse side thereof and at least into the internal surround 13. As best shown in Figures 3 to 6, the internal body 11 includes an in-door portion, which may be located within the thickness of the door or side panel when the letter plate assembly 10 is fitted thereto. In one form, the in-door portion is shaped to correspond to the opening 22. The internal body 11 also includes a flange 25 extending radially outwardly from the in-door portion. The flange 25 shown in Figures 3 to 6 is substantially rectangular and substantially planar. The internal body 11 is fitted relative to the door or side panel so that at least a portion of a reverse surface of the flange 25 abut the surface of the door about the opening 22. A pair of clamping openings 26 extend through the flange 25. Each of the clamping openings 26 are provided with a reinforced surround in the obverse side, the surround being annular surrounding a depression. A plurality of mounting openings 27 are provided in the flange 25 to allow the internal surround 13 to be connected to the flange 25. A shaped groove 28 may be provided in the obverse face of the flange 25 to at least partially seat the projection pin 17 extending from the internal surround 13. The shaped groove 28 shown extends from a lateral side edge toward the centre of the flange 25. The groove 28 is open at an obverse side thereof. A shaped groove 28 is provided on both lateral sides of the flange 25, each extending toward the centre of the flange 25. The in-door portion of the internal body (on the reverse side of the flange 25) include a main connecting slot box 29 and a pair of side mount parts 30, one side mount part 30 on either lateral side of the main connecting slot box 29. The main connecting slot box 29 shown is defined by a number of walls, an upper wall, along wall and a pair of end walls to define a box around the first portion of the main connecting slot in the internal body 11. The dimensions of the main connecting slot box 29 are preferably such that it is closely received within the opening 22 in the door or side panel in order to locate the letter plate assembly 10 in the door or side panel. Each of the side mount parts 30 are spaced from the respective preferred end wall of the main connecting slot box 29. Each of the side mount parts 30 have at least one arcuate or angled outer end wall closer to the lateral edge of the internal body 11. A receiving slot 31 may be provided between the end walls of the main connecting slot box 29 and the side mount part 30 on either lateral end of the internal body 11. The receiving slot 31 receives the respective extension 15 provided on the internal flap 14 when the internal flap 14 is in the closed position. The receiving slot 31 is oriented substantially vertically. The receiving slots 31 are separated from the first portion of the main connecting slot 12. The receiving slots 31 guide movement of the respective extension 15 provided on the internal flap 14 during movement of the internal flap 14. A guide opening 32 is provided through each of the side mount parts 30. The guide opening 32 provided through each of the side mount parts 30 align with a respective clamping opening provided in the internal surround 13. The guide opening 32 extends through the flange 25 of the internal body 11 at the obverse side. The guide opening 32 guides or locates the connector bolt body 24. As best illustrated in Figures 7 to 12, the internal surround 13 has a substantially C-shaped obverse wall 33 when viewed in cross-section, with a pair of end walls 34 to define a hollow volume in a reverse side of the internal surround 13 into which the flange 25 of the internal body 11 is received when the internal subassembly is assembled. A pair of mounting openings 35 are provided through the internal surround 13, each for one of the pair of connecting fasteners 21. Each of the mounting openings 35 may be provided with an annular seat on an obverse side of the internal surround 13. The annular seat (shown in Figure 7) may define a depression or opening into or against which a head of a connector bolt body 24 is seated when the letter plate assembly 10 is assembled. The internal surround 13 has a central opening which is aligned with the main connecting slot 12 through the letter plate assembly. A slot opening 36 is provided spaced from each lateral end of the central opening of the internal surround 13, and through which a respective extension 15 of the internal flap 14 extends. Each of the slot openings 36 is substantially vertical. The internal surround 13 include a corresponding number of receiver ports 37 to receive fasteners therein to mount the internal body 11 to the reverse side of the internal surround 13. Preferably, the receiver ports 37 extend into but not through the internal surround. An elongate slot opening 38 is provided at an upper side of the internal surround 13 on the obverse face to receive and seat a hinge tube 41 of the internal flap 14. A transverse opening may be provided at each end of the elongate slot opening 38 into which a hinge pin (not shown) may mount or fix in order to fix the hinge tube 41 of the internal flap 14 relative to the internal surround 13. In the illustrated embodiment, both end walls 34 of the internal surround 13 include a transverse opening 39 extending through the respective end wall 34 to receive a projection pin 17 (an example is illustrated in Figure 13) extending into the slot opening 16 provided on the respective extension 15 of the internal flap 14. The projection pin 17 is preferably mounted to the end wall 34 of the internal surround 34 and a portion of the projection pin 17 extends into or through the slot opening 16 provided on the respective extension 15 of the internal flap 14. This is shown in Figure 10 in particular by the relative position of slot 36 and transverse opening 39 showing their intersection. The transverse opening 39 in the end wall 34 is at least partially internally threaded. In one embodiment, a larger diameter outer portion is provided, and a smaller diameter inner portion is provided to correspond to a larger diameter outer portion is provided and a smaller diameter inner portion of the projection pin 17 as shown in Figure 13. The larger diameter outer portion may be threaded. The smaller diameter portion may be unthreaded. The projection pin 17 may be correspondingly threaded. The projection pin 17 may include an outer head end provided with shaped engagement portion to engage with a tool. In the illustrated embodiment, the projection pin 17 extends through the end wall 34 of the internal surround 13, be seated against an obverse face of the internal body 11 and extend into or through the slot opening 36 provided on the respective extension 15 of the internal flap 14. The transverse openings 39 extend from a lateral edge of the internal surround 13 toward the main connecting slot 12 to intersect with the slot opening 36 provided on the respective extension 15 of the internal flap 14. A preferred embodiment of the internal flap 14 illustrated in Figures 14 and 15 has a unitary or single piece construction. The internal flap 14 is preferably provided with an aesthetically pleasing appearance. The internal flap 14 may have a main flap portion 40 which is arcuate from top to bottom. A thickened abutment edge is provided along the bottom edge of the internal flap 14 in order to abut the obverse face of the internal surround 13 when the internal flap 14 is closed. The main flap portion 40 may fit within a corresponding rebate in the obverse face of the internal surround 13 which is shown in Figure 7. A hinge tube 41 may be provided at an upper side of the internal flap 14. The hinge tube 41 may extend over a bulk of the length of the top of the flap 14. The hinge tube 41 is preferably hollow. In use, the hinge tube 41 may receive a hinge rod (not shown). The hinge rod may preferably mount the hinge tube 41 relative to the preferred slot opening 38 provided in the obverse surface of the internal surround 13 and allow the internal flap 14 to pivot or rotate about the hinge rod. The hinge rod may have at least one spring-loaded end portion to allow a hinge rod, and the internal flap 14 to be removed from the internal surround 13. Alternatively, one or more fasteners may be provided to mount the hinge rod and / or internal flap 14 relative to the internal surround 13. As mentioned above, a pair of extensions 15 extend from a reverse side of the internal flap 14. The extensions 15 may be referred to as gussets. Preferably, an extension 15 is provided adjacent to, but spaced from both lateral ends of the internal flap 14. The extensions 15 will preferably extend substantially vertically. The extensions 15 will preferably extend substantially perpendicularly from the reverse surface of the internal flap 14. Each of the extensions 15 illustrated is planar, and provided with an arcuate lower edge. The slot opening 16 is provided through each of the extensions 15. In the illustrated form, the slot opening 16 is arcuate to allow the pivot or rotation of the internal flap 14 between the closed end open positions relative to a projection pin 17 which is fixed in position and without requiring any complex pivoting arrangements. The length of the arcuate slot opening 16 will define the opening angle possible of the internal flap 14. At each end of the opening or closing movement of the internal flap 14, the respective projection pin 17 associated with the internal surround 13 will abut the respective end of the slot opening 16. The internal flap 14 will preferably move from a position in which it is substantially vertical in the closed position to a fully open position. Preferably, the slot opening 16 is provided so that the internal flap 14 has an opening of between 30° and 40° when fully open, more preferably between 35° and 40° when fully open and most preferably approximately 37.5° when fully open. In a preferred embodiment, the external surround 19 is attached to the external body 18 and then the external body 18 is mounted to an external side of the door or side panel. Preferably, the external surround 19 may be attached to the internal body 18 using a plurality of fasteners extending through the external body 18 from the reverse side thereof and at least into the external surround 19. The external body 18 includes an in-door portion 42, which may be located within the thickness of the door or side panel when the letter plate assembly 10 is fitted thereto. In the illustrated form, the in-door portion 42 is shaped, having a planar upper and lower surface to be received within the first portion of the main connecting slot in the internal body 11. The downwardly angled shape is defined internally through the in-door portion 42 of the external body 18 as shown in Figure 18. The external body 18 includes a flange 43 extending radially outwardly from the in-door portion 42. The flange 43 illustrated is substantially rectangular and substantially planar. The external body 18 is fitted relative to the door or side panel so that at least a portion of a reverse surface of the flange 43 may abut the surface of the door about the opening. A pair of clamping openings 44 extend through the flange 43. A plurality of mounting openings 45 may be provided in the flange 43 to allow the external surround 19 to be connected to the flange 43. In the illustrated embodiment, a reinforcing member 46 is provided adjacent to the reverse side of the external body 18. The reinforcing member 46 extends below the in-door portion 42 of the external body 18. In one form, the reinforcing member 46 may be a planar and rectangular bar. The reinforcing member 46 is mounted to the reverse face of the external body 18 using fasteners 47 (illustrated in Figure 2) from the reverse side of the external body 18 so that the fasteners are not accessible if the external surround 19 is removed from the external body 18. The in-door portion with the downwardly angled second portion of the connecting slot is preferably aligned with the first portion of the connecting slot during assembly of the letterplate assembly. Preferably, the in-door portion of the external body is received within the in-door portion of the internal body. The external surround 19 has a substantially C-shaped obverse wall when viewed in cross-section with a pair of end walls to define a hollow volume in a reverse side of the external surround 19 into which the flange 43 of the external body 18 is received when the external subassembly is assembled. A pair of mounting openings 48 are provided into the external surround 19, preferably the reverse wall thereof, each for one of the pair of connecting fasteners 17. Each of the mounting openings 48 is provided with an annular seat on a reverse side of the external surround 19. The annular seat will preferably define a depression or opening into which an end of a connector bolt body 24 is seated when the letter plate assembly 10 is assembled. In the illustrated external surround 19, the mounting openings 48 are ‘blind’ openings, extending into the reverse side of the external surround 19, but not through. The external surround 19 preferably has a central opening which is aligned with the main connecting slot 12 through the letter plate assembly 10. The external surround 19 may include a corresponding number of receiver ports 49 to receive fasteners therein to mount the external body 18 to the reverse side of the external surround 19. Preferably, the receiver ports 49 extend into but not through the external surround 19. An elongate slot opening 50 is provided at an upper side of the external surround 19 on the obverse face to receive and seat a hinge tube 52 of the external flap 20. A transverse opening may be provided at each end of the elongate slot opening into which a hinge pin (not shown) may mount or fix in order to fix the hinge tube 52 of the external flap 20 relative to the external surround 19. There are preferably no openings on an obverse side of the external surround except the central opening. The external flap 20 illustrated in Figure 24 has a unitary or single piece construction. The external flap 20 preferably sits within a corresponding rebate in the obverse surface of the external surround as shown in Figure 21. The external flap 20 is preferably provided with an aesthetically pleasing appearance. The external flap 20 has a main flap portion 51 which is arcuate from top to bottom. An enlarged abutment edge is provided along the bottom edge of the external flap in order to abut the obverse face of the external surround 19 when the external flap 20 is closed. A hinge tube 52 may be provided at an upper side of the external flap 20. The hinge tube 52 may extend over a bulk of the length of the top of the flap 20. The hinge tube 52 is preferably hollow. In use, the hinge tube may receive a hinge rod (not shown). The hinge rod may preferably mount the hinge tube 52 relative to the preferred slot opening 50 provided in the obverse surface of the external surround and allow the internal flap to pivot or rotate about the hinge rod. The hinge rod may have at least one spring-loaded end portion to allow a hinge rod, and the internal flap to be removed from the external surround from the reverse side. Alternatively, one or more fasteners may be provided to mount the hinge rod and / or external flap relative to the external surround. Each connecting fastener 17 may be a multipart fastener. In the illustrated form, each connecting fastener 17 comprises two parts, namely a connector bolt body 24 (a form of which is illustrated in Figure 25) and an elongate threaded connector bolt 23 shown in Figure 2. The preferred connector bolt body 24 is preferably mounted to a reverse face of the external surround 19. The connector bolt body 24 may be permanently mounted to the external surround 19. The connector bolt body 24 is preferably provided with an internally threaded bore. The connector bolt body 24 preferably extends from the external surround 19 toward the internal surround 13, extending through the guide openings 32 in the side mount parts 30 of the internal body 11. The connector bolt body 24 may preferably be located within the seats provided in a reverse face of the internal support 13. The threaded connector bolt 23 is preferably inserted from the obverse side of the internal support 13 to engage with the connector bolt body 24 and clamp the external support 19, the external body 18, the internal body 11 and the internal support 13 together through the main opening 22 in the door or side panel so that the respective flanges of the internal body 11 and external body 18 and the external support 19 and internal support 13 abut opposite sides of the door or side panel. The openings in the obverse side of the internal support 13 will be covered by the side portions of the internal flap 14 which are located laterally outside the extensions 15. A gasket 55 is provided between the reverse face of the external body flange 43 and the door or side panel to seal to the external side of the door or side panel. The in-door parts of the internal body and external body and the side mount parts may be surrounded by an annular, intumescent band 56 to provide fire resistance to the letter plate assembly 10. As mentioned above, the letter plate assembly 10 is preferably fitted to the door or side panel through a single cutout opening 22 in the door or side panel. A single tool is preferably used to form the cutout 22 in a single pass. The pair of connecting fasteners 17 are preferably located inside the cutout opening 22. When fitted to the door or side panel, the periphery of opening 22 in the door or side panel will preferably be covered by the respective flanges 25, 43 of the internal body 11 and external body 18 and the internal 13 and external supports 19. In this specification, the term ‘obverse’ refers to the face oriented away from the centre of the door, whereas ‘reverse’ refers to the face oriented toward the centre of the door. The one or more embodiments are described above by way of example only. Many variations are possible without departing from the scope of protection afforded by the appended claims.

Claims

1. A letterplate assembly for a door or side panel, the letterplate assembly comprising:a. an internal subassembly configured to be fitted on an internal side of the door and comprising:i. an internal body defining a first portion of a connecting slot;ii. an internal surround attached to the internal body and mounting an internal flap thereto, the internal flap comprising at least one extension with a slot opening therein,iii. a projection extending from the internal surround at least into the slot opening;b. an external subassembly configured to be fitted on an external side of the door and comprising:i. an external body defining a downwardly angled second portion of the connecting slot aligned with the first portion of the connecting slot;ii. an external surround attached to the external body and mounting an external flap thereto; andc. at least a pair of connecting fasteners mounted between the internal surround and the external surround to clamp the internal subassembly relative to the external subassembly.

2. A letterplate assembly for a door or side panel as claimed in claim 1 wherein the at least one connecting fastener is provided within a footprint of the internal body and / or external body.

3. A letterplate assembly for a door or side panel as claimed in claim 1 or claim 2 wherein at least one, and preferably a plurality of mounting openings are provided in the flange to attach the internal surround to the internal body from a reverse side thereof.

4. A letterplate assembly for a door or side panel as claimed in any one of the preceding claims wherein the internal body includes an in-door portion, and a flange extending radially outwardly from the in-door portion, at least one, and preferably a pair of clamping openings extending through the flange.

5. A letterplate assembly for a door or side panel as claimed in claim 4 further comprising a shaped groove or slot provided in the flange to at least partially seat the projection extending from the internal surround.

6. A letterplate assembly for a door or side panel as claimed in either one of claims 4 or 5 wherein the in-door portion extends from a reverse face of the internal body and comprises a main connecting slot box and a pair of side mount parts, one side mount part on either lateral side of the main connecting slot box.

7. A letterplate assembly for a door or side panel as claimed in claim 6 wherein each of the side mount parts are spaced from the main connecting slot box and a receiving opening is provided between the main connecting slot box and the side mount part on either lateral end of the internal body to receive the at least one extension provided on the internal flap when the internal flap is in the closed position.

8. A letterplate assembly for a door or side panel as claimed in either one of claims 6 or 7 further comprising a guide opening provided through each of the side mount parts to guide or locate one of the pair of connecting fasteners.

9. A letterplate assembly for a door or side panel as claimed in any one of the preceding claims wherein the internal surround has a substantially C-shaped obverse wall with a pair of end walls to define a hollow volume in a reverse side of the internal surround into which the internal body is received when the internal subassembly is assembled.

10. A letterplate assembly for a door or side panel as claimed in claim 9 further comprising at least one, and preferably a pair of mounting openings through the internal surround, each for one of the pair of connecting fasteners.

11. A letterplate assembly for a door or side panel as claimed in either one of claims 9 or 10 wherein the internal surround comprises a central opening aligned withthe main connecting slot through the letter plate assembly and a slot opening is provided spaced from each lateral end of the central opening of the internal surround, and through which a respective at least one extension of the internal flap extends.

12. A letterplate assembly for a door or side panel as claimed in any one of claims 9 to 11 wherein at least one, and preferably both end walls of the internal surround comprise a transverse opening extending through the respective end wall to receive the projection extending into the slot opening provided on the respective at least one extension of the internal flap.

13. A letterplate assembly for a door or side panel as claimed in claim 12 wherein the projection is mounted to the end wall of the internal surround.

14. A letterplate assembly for a door or side panel as claimed in claim 12 or claim 13 wherein the projection extends through the end wall of the internal surround and at least a portion of the projection extends into or through the slot opening provided on the respective at least one extension of the internal flap.

15. A letterplate assembly for a door or side panel as claimed in any one of claims 12 to 14 wherein the transverse opening in the end wall is at least partially internally threaded.

16. A letterplate assembly for a door or side panel as claimed in any one of claims 12 to 14 wherein the transverse opening extends into the internal surround with a larger diameter outer portion provided and a smaller diameter inner portion provided.

17. A letterplate assembly for a door or side panel as claimed in claim 16 wherein the larger diameter outer portion is internally threaded and the smaller diameter portion is unthreaded.

18. A letterplate assembly for a door or side panel as claimed in claim 17 wherein the projection is shaped and threaded to correspond with the transverse opening.

19. A letterplate assembly for a door or side panel as claimed in any one of the preceding claims wherein a projection is provided at both lateral ends of theinternal surround to limit the opening angle of the internal flap on both lateral ends of the internal flap.

20. A letterplate assembly for a door or side panel as claimed in any one of the preceding claims wherein a pair of extensions extend from a reverse side of the internal flap, adjacent to, but spaced from the respective lateral end of the internal flap.

21. A letterplate assembly for a door or side panel as claimed in any one of the preceding claims wherein the slot opening is arcuate to allow the pivot or rotation of the internal flap between the closed end open positions, with the length of the arcuate slot opening defining an opening angle of the internal flap.

22. A letterplate assembly for a door or side panel as claimed in any one of the preceding claims wherein the external surround is attached to the external body from the reverse side thereof.

23. A letterplate assembly for a door or side panel as claimed in any one of the preceding claims wherein the external body includes an in-door portion received within the first portion of the main connecting slot in the internal body and a flange extending radially outwardly from the in-door portion.

24. A letterplate assembly for a door or side panel as claimed in any one of the preceding claims wherein the external surround has a substantially C-shaped obverse wall to define a hollow volume in a reverse side of the external surround into which the external body is received when the external subassembly is assembled.

25. A letterplate assembly for a door or side panel as claimed in any one of the preceding claims comprising at least one, and preferably a pair of blind mounting openings are provided into but not through the external surround, to mount one of the pair of connecting fasteners to clamp the internal subassembly relative to the external subassembly.

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