Access panel assembly

Abstract

Access panel According to the present invention, there is provided an access panel assembly comprising: a frame comprising a fibre-reinforced composite material, the frame configured to define an opening; an access panel configured to be insertable into the opening from a first side of the frame thereby to occlude the opening, the access panel comprising at least one panel retention member; and at least one frame retention member disposed on a second side of the frame opposite to the first side, and configured to be magnetically engageable with a corresponding panel retention member; wherein when the access panel is inserted into the opening, at least one panel retention member magnetically engages with a corresponding frame retention member, thereby to retain the access panel within the opening.

Description

[0001] ACCESS PANEL ASSEMBLY

[0002] Field of the invention

[0003] The present invention relates to access panels for use in ceilings or walls. More specifically, the invention relates to concealed access panels that may be used in surfaces comprising a faced board material, such as plasterboard.

[0004] Background

[0005] Access panels are an integral part of building construction, particularly in areas where there is a need for easy access to services such as plumbing, electrical wiring, or HVAC systems. These panels are typically installed in walls and ceilings, and are designed to blend seamlessly with the surrounding surface while providing a means of access when necessary.

[0006] In the context of plasterboard ceilings, the use of access panels is especially prevalent. Plasterboard, also known as drywall, is a common material used in the construction of interior walls and ceilings due to its ease of installation, cost-effectiveness, and adaptability. However, once installed, accessing the services behind plasterboard can be challenging without causing damage to the surface.

[0007] Traditional access panels for plasterboard ceilings often involve a simple hinged design, where the panel is manually opened and closed as needed. While functional, these designs can be aesthetically unappealing, and may not provide a secure or insulated barrier when closed.

[0008] Traditional access panel designs typically comprise metal frames, hinges and panels. Such frame assemblies are heavy, which can cause issues with installation and operation, and can require additional structural support to be installed in the ceiling. Furthermore, metal frames result in a mismatch of materials between the frame and the surrounding ceiling material, which can cause issues after installation. For example, the mechanical behaviour of the frame will be different to the surrounding wall or ceiling material. Such loading can be cause by, amongst other things, movement in the building, and expansion / contraction due to temperature changes and humidity changes. The mismatch in mechanical response to such effects can cause cracking around the frame assembly. The present invention seeks to address these and other related issues, providing an improved access panel design that is easy to install, operate, and maintain, while offering enhanced aesthetic appeal and insulation properties. The following sections will detail the specific features and advantages of the proposed invention.

[0009] Summary of the invention

[0010] According to a first aspect of the present invention, there is provided an access panel assembly comprising: a frame comprising a fibre-reinforced composite material, the frame configured to define an opening; an access panel configured to be insertable into the opening from a first side of the frame thereby to occlude the opening, the access panel comprising at least one panel retention member; and at least one frame retention member disposed on a second side of the frame opposite to the first side, and configured to be magnetically engageable with a corresponding panel retention member; wherein when the access panel is inserted into the opening, at least one panel retention member magnetically engages with a corresponding frame retention member, thereby to retain the access panel within the opening.

[0011] Existing access panel designs typically use metal frames for insertion into the ceiling or wall. Metal frames are heavy, and exhibit different physical and thermal properties to the ceiling / wall material into which they are inserted, which is typically a faced board material such as plasterboard. These mismatched properties result in cracking developing over time around the access panel assembly. Furthermore, the hinge assembly typically used to allow the access panel to be opened is difficult to fully conceal. Typically, the only way to fully conceal such a panel is to apply concealing material (such as plaster filler and / or paint) over the hinge assembly, which will then be damaged when the panel is opened. Such an arrangement will require the concealing material to be replaced whenever the access panel is opened, which is time consuming and inconvenient.

[0012] The frame of the access panel assembly comprises a fibre-reinforced composite material. This is advantageous because it is lightweight, strong, and exhibits physical and thermal that is similar to those of typical ceiling and wall materials, such as plasterboard.

[0013] Magnetic attraction is used in the retention mechanism, to releasably retain the access panel within the frame of the access panel assembly. This is advantageous as it prevents the need for a hinge mechanism, or similar mechanical means. By removing the need for a hinge mechanism, the access panel can more easily be concealed within the ceiling or wall.

[0014] In an embodiment, there is provided an access panel assembly wherein the fibre- reinforced composite material is non-magnetic. By constructing the frame from a nonmagnetic material, the magnetic retention can be more precisely managed by positioning the magnetic components in the locations where they can releasably engage to retain the panel within the frame. This helps to ensure that the access panel is properly inserted into the frame, such that it is retained within the frame.

[0015] In an embodiment, there is provided an access panel assembly wherein the fibre- reinforced composite material is non-metallic. This is advantageous as it helps to ensure the physical properties of the frame are more closely matched to the non- metallic materials that comprise the ceiling and wall materials into which the frame assembly is inserted, which is typically a faced board material such as plasterboard.

[0016] In an embodiment, there is provided an access panel assembly wherein the fibre reinforced composite material comprises a sulphate mineral. This is advantageous because such materials exhibit good mechanical and thermal properties, and are also inexpensive and easy to manufacture.

[0017] In an embodiment, there is provided an access panel assembly wherein the fibre- reinforced composite material comprises fibre reinforced gypsum. This is advantageous because fibre reinforced gypsum has similar mechanical and thermal properties to typical ceiling and wall materials, which often comprise gypsumcontaining materials such as plasterboard. Fibre reinforced gypsum also exhibits good mechanical properties, and is inexpensive and easy to manufacture into the required components.

[0018] In an embodiment, there is provided an access panel assembly wherein the fibre- reinforced composite material comprises glass fibre reinforced gypsum. This is advantageous because glass fibres significantly improve the mechanical properties of the reinforced gypsum composite material.

[0019] In an embodiment, there is provided an access panel assembly wherein the opening has a quadrilateral shape. This is advantageous because such a shape allows the access panel assembly to be easily installed into a ceiling or wall, while providing suitable access into the space above / behind the ceiling / wall.

[0020] In an embodiment, there is provided an access panel assembly wherein the frame comprises two or more frame components connected together to form the frame. This is advantageous because may allow for the frame to be transported in

[0021] In an embodiment, there is provided an access panel assembly wherein the or each panel retention member is or includes a magnet and / or wherein the or each frame retention member is or includes a magnet. This is advantageous because magnets allow for the access panel to be releasably retained within the frame, without the need for mechanical retention means such as a hinge mechanism, which would otherwise add to the weight and complexity of the access panel assembly.

[0022] In an embodiment, there is provided an access panel assembly according to any previous claim, wherein the opening has at least four corners. This is an advantageous shape for the opening in order to facilitate ease of use for access through the access panel assembly. Furthermore, this shape allows for the access panel assembly to be more easily installed, for example in a ceiling.

[0023] In an embodiment, there is provided an access panel assembly, wherein the access panel has at least four corners. This is an advantageous shape in order to facilitate ease of use for access through the access panel assembly. Furthermore, this shape allows for the access panel assembly to be more easily installed, for example in a ceiling.

[0024] In an embodiment, there is provided an access panel assembly comprising two or more panel retention members each being positioned proximate to a different corner of the access panel. Positioning the retention members in this manner is advantageous in ensuring that the weight of the access panel is evenly distributed between the retention members, in order to help ensure the access panel is securely retained when it is inserted into the opening.

[0025] In an embodiment, there is provided an access panel assembly wherein at least two of the two or more panel retention members are each positioned proximate to non- adjacent corners of the access panel. This is advantageous because by positioning the retention members proximate to non-adjacent corners, the weight of the access panel can be evenly distributed between the various retention members, thereby securely retaining the panel within the frame.

[0026] In an embodiment, there is provided an access panel assembly wherein at least one panel retention member is positioned proximate to each of the corners of the access panel. This is advantageous because adding additional retention members may increase the retaining force, while also distributing the weight of the access panel more evenly across the retention members in the access panel assembly.

[0027] In an embodiment, there is provided an access panel assembly comprising an equal number of panel retention members and frame retention members. This is advantageous because it ensures the retention members are evenly distributed between the frame and the panel, thereby helping distribute the weight of the access panel evenly between the retention members.

[0028] In an embodiment, there is provided an access panel assembly wherein each of the panel retention members is configured to be magnetically engageable to a different frame retention member. This is advantageous because it helps to distribute the weight of the access panel evenly between the retention members.

[0029] In an embodiment, there is provided an access panel assembly wherein each of the at least one frame retention members is configured to at least partially extend across the second side of the opening. This advantageously improves the engagement between the panel retention members and the frame retention members. In examples where the access panel assembly is installed in a ceiling, this also advantageously ensures that the magnetic engagement is aligned to the gravitational force acting on the access panel. This improves the security and stability of the magnetic engagement, by ensuring the magnetic attraction is acting against a linear force rather than a shear force.

[0030] In an embodiment, there is provided an access panel assembly further comprising a releasable securing assembly configured to allow for the access panel to be releasably attached to an external component. This is advantageous because it provides an additional safety measure to prevent the access panel from falling to the ground, in the event that the magnetic retention is inadvertently released. This is also beneficial when the magnetic retention is intentionally released, as it prevents the access panel from being entirely detached and potentially falling on a user. In an embodiment, there is provided an access panel assembly wherein the releasable securing assembly comprises: a first component attached to the access panel; and a second component configured to be attached to an external component, and to be releasably attachable to the first component. This is advantageous because it allows for the panel to be securely attached to an external component such as a ceiling beam, while also allowing for the panel to be easily detached from the releasable securing assembly, as needed.

[0031] In an embodiment, there is provided an access panel assembly wherein the first component of the releasable securing assembly comprises a hook. This is advantageous because a hook provides a secure but easily releasable connection between the access panel and the remainder of the securing assembly.

[0032] In an embodiment, there is provided an access panel assembly wherein the second component of the releasable securing assembly comprises a chain, wire, and / or cable. This is advantageous because these options all provide a flexible but secure means for securing the access panel until the releasable securing assembly is released.

[0033] Brief description of the figures

[0034] Examples of the present invention will now be described in detail with reference to the accompanying drawings, in which:

[0035] Figure 1 illustrates an access panel assembly according to the present disclosure;

[0036] Figure 2 illustrates the access panel assembly illustrated in Figure 1, viewed from direction A;

[0037] Figure 3 illustrates an access panel assembly according to the present disclosure, shown in an exploded view to more clearly illustrate examples of the components;

[0038] Figure 4 illustrates an example of a releasable securing assembly, according to the present disclosure; and

[0039] Figure 5 illustrates a further examples of an access panel assembly according to the present disclosure. Detailed description

[0040] Figure 1 illustrates an access panel assembly 100 according to the present disclosure. The access panel assembly 100 comprises a frame 101 and an access panel 201. In the illustration, the access panel 201 is shown in a position where it is releasable retained within the frame 101. In the illustration, the access panel assembly 100 is illustrated from above, while in a horizontal orientation. This would typically be the orientation used when the access panel assembly 100 is used in a horizontal ceiling. Such an arrangement will be assumed when describing examples throughout this description, with terms such as "above" and "below" being used in relation to such an orientation. However, it should be appreciated that the access panel assembly 100 could be used in any orientation, including in sloping ceilings or in walls without significant modification. Therefore, in order to prevent unnecessary repetition of information, use of the access panel assembly 100 such orientations will not be described in further detail.

[0041] Figure 2 illustrates an access panel assembly 100 viewed from below. For clarity, the viewing direction of this illustration is indicated as "A" in Figure 1. The illustrated access panel assembly 100 comprises a frame 101 and an access panel 201. In the illustrated example, the frame 101 is shown as comprising a first frame component 102 and a second frame component 103. This is illustrated in more detail in other figures.

[0042] In some examples, the frame 101 may comprise only a single component. A frame comprising only one component may have improved mechanical properties, due to the absence of any joints or connections. Such a frame may also be lighter, as it does not require the inclusion of any means for connecting together frame components.

[0043] In some examples, a frame 101 may comprise two or more components connected together. Such examples may be easier to manufacture, transport and install. By comprising multiple components, it may be possible to construct different frame shapes using a set of standard frame components. This may be advantageous in allowing for access panel assemblies with various shapes and dimensions to be constructable, while only requiring a limited number of frame components to be manufactured, allowing for greater flexibility in the applications of the access panel assemblies, while limiting the variety of components that need to be manufactured. In such examples, the frame components may be joined using any suitable means. As shown in Figure 3, the frame components may be connected using a connection member 104. The frame 101 may comprise any suitable fibre-reinforced composite material. In some examples, the fibre-reinforced composite material comprises glass fibre reinforced gypsum (GRG). GRG is advantageous because it is strong, robust, lightweight, and is easy to machine.

[0044] In some examples, the material of the frame 101 may be adapted to provide specific properties. For example, a specific type of fibre- reinforced composite material may be used in applications where enhanced fire resistance is required. An example of such a material is "Glasroc F FIRECASE", which is a gypsum-based material that comprises a tissue of glass fibre immediately below the surface. The core of the material comprises glass fibre reinforcement and paper pulp material. This material exhibits enhanced fire resistance.

[0045] The access panel assembly 100 illustrated in figure 2 comprises four centre lugs 106, extending outwards from the edge of the frame 101. These help with installation and retention of the access panel assembly within the ceiling (or wall). They also help to distribute the weight of the access panel assembly 100 around the point of insertion, thereby helping to prevent damage to the surrounding material. The illustrated example also shows parts of the frame retention members 301 extending outwards beyond the edge of the frame. These extended portions help to distribute the weight of the access panel 201 when it is retained in the frame 101 by the frame retention members 301. In some examples, these extended portions may not be present, or may be arranged differently.

[0046] Figure 3 illustrates an exploded view of the access panel assembly 100, such that the various components can more easily be viewed. As with figure 1, figure 3 illustrates the access panel assembly 100 from above.

[0047] The illustrated access panel 201 comprises a front panel 202, and a back plate 204. The front panel may comprise any suitable material, but is typically selected to be similar to the ceiling material into which the access panel assembly 100 is to be installed. Typically, the ceiling material will be a faced board material, such as plasterboard. In such an example, the front panel 202 comprises a plasterboard panel. Typically, the plasterboard front panel 202 will be prepared such that the facing paper extends across the front face and over each of the edges such that the plaster material is not exposed at the edges of the panel. This can help to prevent damage to the plaster material when the access panel 201 is inserted or removed from the frame 101. In the illustrated example, the front panel 202 is bonded to a back panel 204. This can help to provide structural strength to the access panel 201. The back panel 204 may comprise any suitable material, and may be bonded to the front panel 202 with any suitable means. In some examples, the back panel 204 may comprise a metal sheet, and may be glued to the front panel 202.

[0048] In some examples, a layer of compressible material such as neoprene may be included between the front panel 202 and the back panel 204. In some examples, the layer of compressible material may include open spaces surrounded by compressible material, thereby to create air pockets. Such a layer of compressible material (including examples where open spaces are included) may help to improve the acoustic isolation of the access panel 201, and thus of the access panel assembly 100.

[0049] In the illustrated example, the access panel 201 further comprises seals 205 disposed around the edge of the access panel 201. Such seals may help to close the gap between the access panel 201 and the frame 101, when the access panel 201 is inserted and retained within the frame 101. The seals 205 may allow for a small gap to be present, thereby improving the ease with which the access panel 201 can be inserted and removed, while also limiting air flow through such a gap. The presence of a gap may also allow for a removal tool to be inserted between the access panel 201 and the frame 101, thereby facilitating the removal of the access panel 201. Limiting the airflow through such a gap can be beneficial in improving the acoustic and / or thermal isolation provided by the access panel assembly 100. In some examples, the seals 205 may be brush seals.

[0050] The illustrated access panel 201 comprises four panel retention members 203, each located proximate to a different corner of the access panel 201. In the illustrated example, each of the panel retention members 203 is a permanent magnet, such as a neodymium magnet. In the illustrated example, the frame 101 comprises four frame retention members 301, each located proximate to a different corner of the frame 101. In the illustrated example, each of the frame retention members comprises a ferromagnetic metal, such as steel.

[0051] In the illustrated example, when the access panel 201 is inserted into the frame 101, the four permanent magnets (the panel retention members 203) are magnetically attracted to each of the respective frame retention members 301. The access panel 201 is thereby releasably retained within the frame 201 by this magnetic attraction. The illustrated example shows the panel retention members 203 comprising four permanent magnets, and the frame retention members 301 comprising a ferromagnetic metal. However, it should be appreciated that this is merely one example of how the releasable magnetic retention mechanism could be implemented. For example, one or more of the panel retention members 203 could instead comprise a ferromagnetic metal, and the corresponding frame retention members 301 could comprise a magnet. In some examples, a corresponding panel retention member 203 and frame retention member 301 could each comprise a magnet, arranged in an appropriate orientation in order to facilitate magnetic retention of the access panel 201 within the frame 101. In some examples, one or more of the magnets disposed within the access panel assembly 100 may be an electromagnet. This could be advantageous in allowing for the magnetic retention of the access panel 201 within the frame 101 to be released without the need for mechanical separation.

[0052] In some examples, as few as two magnetic connections may be suitable for retaining the access panel 201 within the frame 101. In such examples, the retention members may be arranged in opposing corners, thereby to help evenly distribute the weight of the access panel 201.

[0053] In some examples, access panel assembly 100 may comprise a mismatched number of panel retention members 203 and frame retention members 301. For example, the frame 201 may comprise a fewer number of frame retention members 301 thereby to help to reduce the weight of the access panel assembly 100. In another example, the access panel 201 may comprise fewer permanent magnets, thereby to help reduce the cost of the access panel assembly 100. In some examples, either the frame 101 or the access panel 201 may comprise a retention member located proximate to each respective corner, even if the other component has a reduced number of retention members. This may be advantageous in allowing for the access panel 201 to be inserted in any rotational orientation, since if at least one of the access panel 201 or the frame 101 has a retention member located proximate to each respective corner, then then maximum number of magnetic engagements will occur, even if some corners do not have a pair of retention members.

[0054] Figure 4 illustrates an example of a releasable securing assembly 400, according to the present disclosure. The illustrated example comprises a first component 401 and a second component 402. In the illustrated example, the first component 401 comprises a hook that may be securely attached to the upper face of the access panel 201, and the second component 402 comprises a cable 405. The second component 402 further comprises an external component attachment 404 that may be securely attached to an external component, such as a ceiling beam located above the access panel assembly 100. The second component 402 further comprises a releasable attachment 403 that is releasably engageable with the first component 401. In the illustrated example, the releasable attachment 403 comprises a loop that is releasably engageable with the hook of the first component 401. In use, the loop 403 is attached to the hook 401 before the access panel 201 is inserted into the frame 101. Then, when the access panel 201 is released from the frame 101 (either intentionally or inadvertently), the releasable securing assembly 400 prevents the panel 201 from being entirely released from the access panel assembly 100. Typically, the length of the cable 403 of the releasable securing assembly 400 will be selected to be long enough that the access panel 201 can be sufficiently removed from the frame in order to allow for the releasable securing assembly 400 to be manually released, while being short enough to prevent the access panel 201 from dropping far enough from the ceiling to cause injury to anyone standing below.

[0055] Figure 5 illustrates a further example of an access panel assembly 500 according to the present disclosure. In the illustrated example, the access panel assembly 500 is illustrated as viewed from below (for example, if it is installed in a ceiling). The access panel assembly 500 comprises a frame 501, and an access panel 502. It should be appreciated that while the frame opening will typically have a substantially square opening, as illustrated in Figures 1-3, other opening shapes are contemplated.

[0056] In the example illustrated in Figure 5, the opening in the frame 501 is a substantially circular shape. In other examples, the opening may have other shapes, for example a substantially oval shape, or a substantially square shape but with rounded corners. Each shape may be beneficial for particular applications. The access panel 502 in the illustrated example is also substantially circular, thereby to substantially fill the opening when the access panel 502 is inserted into the opening in the frame 501.

[0057] It should be appreciated that an access panel according to the present disclosure may be of any shape, and will be configured so as to substantially fill the opening in the frame of an access panel assembly. The shape of the access panel will therefore typically be substantially the same as the shape of the opening in the frame, such that when inserted into the opening, the access panel substantially fills the opening. In examples, the one or more retention members are arranged such that they are able to magnetically retain the access panel within the opening, when the access panel is inserted into the opening. In the example illustrated in Figure 5, the retention members are not shown. However, they may be positioned in any suitable arrangement. For example, one or more panel retention members may be disposed proximate to an edge of the access panel. One or more frame retention members may be positioned such that when the access panel is inserted into the opening, the panel retention members each magnetically engage with at least one frame retention member, thereby to retain the access panel within the opening.

[0058] As discussed previously in relation to other illustrated examples, the particular arrangement of panel and frame retention members may vary. As discussed previously, each pair of retention members (panel retention member and frame retention member) will comprise at least one magnetic component, which will typically be a permanent magnet (such as a neodymium magnet). For each pair of retention members, he magnetic component may be disposed in the access panel (as part of the panel retention member) and / or in the frame (as part of the frame retention member).

[0059] It should be understood that the illustrated examples disclosed herein are merely exemplary, and that further examples may be provided with additional or fewer features while still falling within the scope of the appended claims. Likewise, the shape and dimensions of examples within the scope of the appended claims may differ from those illustrated.

Claims

CLAIMS1. An access panel assembly comprising: a frame comprising a fibre-reinforced composite material, the frame configured to define an opening; an access panel configured to be insertable into the opening from a first side of the frame thereby to occlude the opening, the access panel comprising at least one panel retention member; and at least one frame retention member disposed on a second side of the frame opposite to the first side, and configured to be magnetically engageable with a corresponding panel retention member; wherein when the access panel is inserted into the opening, at least one panel retention member magnetically engages with a corresponding frame retention member, thereby to retain the access panel within the opening.

2. The access panel assembly according to claim 1, wherein the fibre- reinforced composite material is non-magnetic.

3. The access panel assembly according to any previous claim, wherein the fibre- reinforced composite material is non-metallic.

4. The access panel assembly according to any previous claim, wherein the fibre reinforced composite material comprises a sulphate mineral.

5. The access panel assembly according to any previous claim, wherein the fibre- reinforced composite material comprises fibre reinforced gypsum.

6. The access panel assembly according to any previous claim, wherein the fibre- reinforced composite material comprises glass fibre reinforced gypsum.

7. The access panel assembly according to any previous claim, wherein the opening has a quadrilateral shape.

8. The access panel assembly according to any previous claim, wherein the frame comprises two or more frame components connected together to form the frame.

9. The access panel assembly according to any previous claim, wherein the or each panel retention member is or includes a magnet.

10. The access panel assembly according to any previous claim, wherein the or each frame retention member is or includes a magnet.

11. The access panel assembly according to any previous claim, wherein the opening has at least four corners.

12. The access panel assembly according to any previous claim, wherein the access panel has at least four corners.

13. The access panel assembly according to claim 12, comprising two or more panel retention members each being positioned proximate to a different corner of the access panel.

14. The access panel assembly according to claim 13, wherein at least two of the two or more panel retention members are each positioned proximate to non-adjacent corners of the access panel.

15. The access panel assembly according to any of claims 12 to 14, wherein at least one panel retention member is positioned proximate to each of the corners of the access panel.

16. The access panel assembly according to any previous claim, comprising an equal number of panel retention members and frame retention members.

17. The access panel assembly according claim 16, wherein each of the panel retention members is configured to be magnetically engageable to a different frame retention member.

18. The access panel assembly according to any previous claim, wherein each of the at least one frame retention members is configured to at least partially extend across the second side of the opening.

19. The access panel assembly according to any previous claim, further comprising a releasable securing assembly configured to allow for the access panel to be releasably attached to an external component.

20. The access panel assembly according to claim 19, wherein the releasable securing assembly comprises: a first component attached to the access panel; and a second component configured to be attached to an external component, and to be releasably attachable to the first component.

21. The access panel assembly according to claim 20, wherein the first component comprises a hook.

22. The access panel assembly according to claims 20 or 21, wherein the second component comprises a chain, wire, and / or cable.

Images