WO2019086089A1

WO2019086089A1 - A socket element and method for installation of a socket element into a wall

Info

Publication number: WO2019086089A1
Application number: PCT/DK2018/050274
Authority: WO
Inventors: Brian Bjørnskov Vase PEDERSEN
Original assignee: NORCONSOL HOLDING APS
Current assignee: NORCONSOL HOLDING APS
Priority date: 2017-11-06
Filing date: 2018-10-29
Publication date: 2019-05-09
Anticipated expiration: 2020-05-06
Also published as: EP3707793A4; DE202018006898U1; EP3707793A1

Abstract

A socket element (10) for installation of an electrical socket in a wall insulation (54) comprising along an insertion direction (40) a mounting aperture (12) connected to a flange (30), which is connected to an insertion end (14). The flange comprises a centrally-positioned flange aperture (32) and a flange face (34) defining a flange plane (42), which is perpendicular to the insertion direction (40). The flange face may have a plurality of structure gaps (36). Use and a method of mounting said socket element in a wall are also disclosed.

Description

A socket element and method for installation of a socket element into a wall

Field of the Invention

The present invention relates to a socket element enabling installation of an electrical socket in a wall without creating moisture bridges, which are a substantial problem for installations in walls facing the ambient atmosphere.

The present invention relates to a socket element enabling installation of an electrical socket in an insulated facade system without creating moisture bridges without sacri- ficing load capacity of the socket element by distributing any external force to the surrounding plaster.

Background of the Invention

The installation of an electrical socket in a wall face, which is in direct contact with ambient atmosphere, is at present cumbersome and expensive due to installation time and material cost.

As an example the installation of an electric socket on a wall comprising a concrete wall having an outer layer of insulation requires an inner element made of hard poly- styrene in direct contact with the concrete wall. The electric socket is connected to the inner element. The cost of the materials alone is roughly DKK 200-350 or 30-50 EUR. On top of the material cost is the cost of work, which is of a substantial size due to the amount of work, i.e. connecting the inner element with the concrete and the adjustment of the insulation material.

Furthermore, the electric socket has a problem with moisture traveling along the intersection between the electric socket and the insulation due to a poor connection between the sides of the electric socket and plaster. The installation of air ducts in a wall face, which is in direct contact with ambient atmosphere, suffers from moisture diffusion along the surface of the air ducts. The air ducts are made of metal and this is part of the problem, as the adhering characteristic between metal and plaster is poor, thus plaster on the metal will over time crack, thereby enabling moisture to travel along the interface between air duct and insulation.

Thus there is a need for an inexpensive socket capable having an improved moisture blocking power relative to the prior art.

The above-mentioned problems are especially related to insulated facade system.

Present day socket elements must, when installed in insulation of a wall or an insulat- ed facade system, be compliant with IP44.

Object of the Invention

It is an object of the invention to overcome the limitations of the prior art by providing a new and inventive socket element for installation of an electrical socket or air ducts in a wall, such as an insulated facade system.

Description of the Invention

An object is achieved by a socket element for installation of an electrical socket or an air duct in a wall. The socket element may comprise along an insertion direction a mounting aperture connected to a flange, which is connected to an insertion end. The flange may comprise a centrally-positioned flange aperture and a flange face defining a flange plane. The flange plane is perpendicular to the insertion direction. The flange face may have a plurality of structure gaps. The socket element may have a shape complementary to the electrical socket or air duct.

The socket element is adapted to be installed in a wall having a wall face before plaster is applied, i.e. while the insulation of the wall is exposed. There may be carved a hole in the insulation. The carved hole may have a complementary shape to the socket element to be inserted.

The serviceman may drill or cut a hole in the insertion end for pulling a wire through or for a tight connection with an end of an air duct. Afterwards the socket element may be inserted into the hole until the flange connects with insulation in such a manner that the flange face is parallel with the insulation. Afterwards plaster may be applied to the insulation and to the flange, where the interaction between a plurality of structure gaps and the applied plaster ensures a stable connection, which has a greater moisture blocking power.

Thus, the socket element may be installed in the insulation without screws or rods or the like, which extend through the insulation to the load- bearing wall. Thus, the socket element of the invention differs from the prior art by distributing any force acted on the socket element to the plaster through the flange, where the prior art distribute any force acted on the prior art socket element to the load-bearing wall through screws or rods or the like.

In this way the socket element becomes an inexpensive solution to installation of electric sockets or air ducts, while solving the problems relating to diffusion of moisture.

In an embodiment the insertion end is connected to the flange by a cylinder.

In another embodiment the insertion end is connected to the flange by a box-shaped structure.

The connection structure connecting the insertion end and the flange may have any given shape as long as it has a sufficient strength.

In an embodiment the mounting aperture is connected to the flange by a cylinder.

In another embodiment the mounting aperture is connected to the flange by a box- shaped structure.

The connection structure connecting the mounting aperture and the flange may have any given shape as long as it has a sufficient strength. In an aspect the insertion end may comprise a connection aperture for pulling a wire or connection with an air duct.

The connection aperture will ease the installation of the socket element as it is already adapted for the accommodated wires or an air duct.

When the connection aperture is for an air duct, the connection aperture will have an area similar to the insertion end. The air duct will typically be installed in a wall face before the socket element. The socket will then be installed into the wall by pushing into the air duct. When the socket element is adapted for installation of an air duct in a wall face, the connection aperture and insertion end will have a cross section complementary to the air duct. One or more screws may be screwed through the connection structure between the flange and the insertion end and the air duct. This will make for a stronger connection between the socket element and the air duct.

In another embodiment of the socket element the connection structure between the flange and the insertion end is angled up to three degrees relative to the normal of the flange such that the insertion end has a cross section smaller than the cross section of the connection structure at the flange. The socket element is then forced into the air duct which creates a strong and moisture tight connection without damaging either structure.

In an embodiment the socket element may comprise locking means between the flange and the mounting aperture for holding a grating. The grating is part of the air duct system and is needed for preventing leaves and such to enter the air duct system. In an embodiment the locking means is formed as a groove being in a plane parallel to the flange face, thus forming a female socket for the grating.

In an aspect the socket element may be a monolith. By making the socket element as a monolith the cost of production is lowered.

In an embodiment the socket element may be in a plurality of pieces, which can be assembled into the socket element. This enables a greater degree of freedom when forming the socket as different flanges may have different positive effects.

In an aspect the socket element may be made of ABS.

ABS is an inexpensive and water impermeable material being suitable for the socket element. Furthermore, the connection between ABS and plaster is good and stable. Thus, the interface between the socket element and the plaster will not begin to crack.

The socket element may be made in different water impermeable material. In an embodiment the flange will be thickest near the flange aperture and thinnest near an outer periphery of the flange. This feature creates a better connection between the socket element and the plaster.

In another embodiment the flange may have a uniform thickness as this creates a stronger flange.

In an embodiment, the plurality of structure gaps is substantially elongated. The plurality of structure gaps can be divided into two groups, where the structure gaps in each group are substantially parallel to each other and the structure gaps are substan- tially perpendicular to the structure gaps of the other group.

Tests have shown that elongated structure gaps which are mutually perpendicular result in a strong adhesiveness with plaster when in intended use. In an aspect of the invention, the socket element may comprise a connection channel between the flange and the insertion end. The connection channel may extend perpendicularly relative to the insertion direction. The connection channel may be adapted for interlinking with another connection channel of another socket element. Thereby, two or more socket elements may form a socket system that increases the volume which can be used to support electric equipment.

The connection channel may extend beyond the flange, such that the interlinking be- tween two connection channels is made easier.

In an embodiment, an extension channel interlinks two connection channelsthat would otherwise not be able to reach each other because the flanges of the two socket elements have a larger extend and therefore would prevent the interlinking of connection channels.

A user may remove part of the flange by sawing or the like such that the connection channel extends beyond the flange. In an aspect of the invention, the flange may comprise a flange break line arranged in the flange above the connection channel, such that part of the flange is removable.

The flange break line may be defined by having no structure gaps along the flange break line, such that a user may easily cut along the flange break line without weaken- ing the structure.

The flange may be structurally weakened along the flange break line, such that part of the flange is more easily removed. The flange break line may be defined by having a few elongated structure gaps along the entire flange break line, such that a user may easily break part of the flange of the socket element.

The flange may be structurally weakened between the few elongated structure gaps along the entire flange break line such that part of the flange is more easily removed.

In an aspect of the invention, the socket element may comprise a second connection channel positioned between the flange and the insertion end. The second connection channel may extend perpendicularly relative to the insertion direction and may be adapted for interlinking with another connection channel of another socket element.

In an embodiment, the first and second connection channels are positioned on oppo- site sides of socket element.

In an embodiment, the first and second connection channels are positioned on the socket element, such that they form define a substantially 90 degree angle. In an embodiment, the socket element has a plurality of connection channels.

In an aspect of the invention, the flange comprises a second flange break line arranged in the flange above the second connection channel. In an embodiment, the flange comprises a plurality of flange break lines arranged above a plurality of connection channels.

An object of the invention is achieved by an insulated facade system comprising one or more socket elements.

The one or more socket elements may be installed in the insulated facade system as shown in fig. 3 or fig. 8.

Each socket element may be installed in the insulated facade system by drilling or carving in insulation a hole complementary to the socket element. The socket element may afterwards be inserted into the hole, such that the flange of the socket element interacts with the insulation. A first layer of plaster may afterwards be applied to the insulation and the flange. A reinforcement mesh may afterwards be applied to the first layer of plaster and there may be a second layer of plaster on the reinforcement mesh.

Thus, the socket element may be installed in the insulation without screws or rods or the like, which extend through the insulation to the load-bearing wall. The socket element of the invention differs from the prior art by distributing any force acted on the socket element to the plaster and reinforcement mesh through the flange, where the prior art distribute any force acted on the prior art socket element to the load-bearing wall through screws or rods or the like.

Each socket element is in this way very strongly secured to the insulated facade sys- tern and the moisture blocking power is high.

The socket element can be properly installed in the insulated facade system without screws or nails. Thereby, the moisture blocking power is increased relative to socket elements installed using screws or nails.

In an aspect, the insulated facade system may comprise one or more socket elements having one or more connection channels, which can be interconnected, thereby forming a socket system. In an aspect of the invention, the one or more socket elements may be positioned in insulation of the insulated facade system and the mounting aperture faces away from the insulated facade system. A first layer of plaster may be arranged on the flange, a reinforcement mesh may be arranged on the first layer of plaster and a second layer of plaster may be arranged on the reinforcement mesh.

The one or more socket elements are in this way mechanically secured to the insulated facade system by the layers of plaster and the reinforcement mesh. The one or more socket elements also have a high moisture blocking power. The insulated facade system may be an exterior insulated facade system facing ambient atmosphere i.e. the external atmosphere.

A method for installing a socket element in a wall, the method comprises one or more acts.

There may be an act of providing a socket element.

There may be an act of pre-carving in insulation a hole complementary to the socket element.

There may be an act of inserting the socket element into the hole.

There may be an act of applying plaster on the flange and the insulation. There may be an act of applying a reinforcement mesh on the plaster.

There may be an act of applying plaster on the reinforcement mesh. Thus, the socket element may be installed in the insulation without screws or rods or the like, which extend through the insulation to the load-bearing wall. The socket element of the invention differs from the prior art by distributing any force acted on the socket element to the plaster and reinforcement mesh through the flange, where the prior art distribute any force acted on the prior art socket element to the load-bearing wall through screws or rods or the like. This also enables an easier and faster installation of the socket element compared to the prior art, while maintaining a high load capacity.

Example

The socket element is to be installed in a wall having a wall face of insulation as plaster is yet to be applied.

A user pre-carves in the insulation a hole complementary to the socket element. The term pre-carve should be interpreted broadly as the hole may be drilled by a cup drill. This is followed by the insertion of the socket element into the hole.

The plaster may then be applied to the flange and the insulation. Thus the socket element is in an easy manner installed in a wall.

A method for installing a socket element in a wall, the method comprises one or more acts of.

There may be an act of providing a socket element adapted for an air duct.

There may be an act of providing a wall face comprising insulation and an air duct. There may be an act of inserting the socket element into the air duct.

There may be an act of applying plaster on the flange and the insulation. Example:

A method for installing a socket element in an insulated facade system, the method comprises an act of providing a socket element.

There may be a further act of pre-carving or drilling in insulation a hole complementary to the socket element. There may further be an act of inserting the socket element into the hole.

There may further be an act of applying a first layer of plaster on the flange and the insulation.

There may be an act of applying a reinforcement mesh on the first layer of plaster. There may be an act of applying second layer of plaster on the reinforcement mesh.

Example

The socket element adapted for an air duct is to be installed in a wall comprising a wall face of insulation as plaster is yet to be applied and a pre-installed air duct which is yet to be properly secured to the wall.

In this case the socket element is inserted into the air duct.

The plaster may then be applied to the flange and the insulation. Thus the socket element and air duct is in an easy manner installed in a wall. An object of the invention is achieved by use of a socket element for installing an electrical socket in a wall.

An object of the invention is achieved by use of a socket element for installing an air duct in a wall.

An object of the invention is achieved by use of a socket element for installing an electrical socket in an insulated facade system.

An object of the invention is achieved by use of two or more socket elements compris- ing connection channels for installing a socket system in an insulated facade system.

The air duct is installed in the wall, when plaster is applied to the wall.

Description of the Drawing

Embodiments of the invention will be described in the figures, whereon:

Fig. 1 illustrates a socket element;

Fig. 2 illustrates a front view of a socket element; Fig. 3 illustrates a side view of a socket element before and after installation in a wall face;

Fig. 4 illustrates a socket element having a substantially circular shape;

Fig. 5 illustrates a side view of a socket element comprising locking means;

Fig. 6 illustrates a side view of a socket element connected to an air duct after installation in a wall; and

Fig. 7 illustrates a socket element comprising connection channels;

Fig. 8 illustrates a side view of a socket element comprising connection channels before and after installation in a wall face;

Fig. 9 illustrates the method of installing a socket element in a wall.

Socket element 10

Mounting aperture 12

Insertion end 14

Connection aperture 16

Locking means 18

Connection channels 20

Flange 30

Flange aperture 32

Flange face 34

Plurality of structure gaps 36

Flange break line 38

Insertion direction 40

Flange plane 42

Wall 50

Wall face 52

Insulation 54

Plaster 56

Load-bearing structure 58

Air duct 59

Method for installing a socket element 100

Act of providing 110

Act of pre-carving 120 Act of inserting 130

Act of applying 140

Detailed Description of the Invention

Fig. 1 illustrates a socket element 10 for installation of an electrical socket or an air duct. The socket element 10 comprises along an insertion direction 40 a mounting aperture 12 connected to a flange 30. The flange 30 is connected to an insertion end 14. The flange 30 comprises a centrally-positioned flange aperture 32 and a flange face 34, which defines a flange plane 42 being perpendicular to the insertion direction 40. The flange face 34 has a plurality of structure gaps 36. Each structure gap of the plurality of structure gaps 36 has a shape which extends in a direction perpendicular to an outer periphery of the flange 30.

Fig. 2 illustrates a front view of a socket element 10 for installation of an electrical socket or an air duct. The socket element 10 comprises along an insertion direction 40 a mounting aperture 12 connected to a flange 30. The flange 30 is connected to an insertion end 14. The flange 30 comprises a centrally-positioned flange aperture 32 and a flange face 34, which defines a flange plane 42 being perpendicular to the insertion direction 40. The flange face 34 has a plurality of structure gaps 36. Each structure gap of the plurality of structure gaps 36 has a shape which extends in a direction perpendicular to an outer periphery of the flange 30.

Fig. 3 illustrates a side view of a socket element 10 before (A) and after (B) installation in a wall face 52. The socket element 10 is for installation of an electrical socket or an air duct. The socket element 10 comprises along an insertion direction 40 a mounting aperture 12 connected to a flange 30. The flange 30 is connected to an insertion end 14. The flange 30 comprises a centrally-positioned flange aperture 32 and a flange face 34, which defines a flange plane 42 being perpendicular to the insertion direction 40. The flange face 34 has a plurality of structure gaps 36. The socket element 10 is installed into a wall 50. The wall 50 comprises a load- bearing structure 58, insulation 54 and plaster 56. The insulation 54 defines the wall face 52 on which plaster 54 and the flange 30 is placed. The socket element 10 has been inserted into a hole in the insulation 54 and plaster 56 has been provided on the wall face 52. In this way a stable and moisture tight connection is created between the socket element 10 and the wall 50.

Fig. 4 illustrates a socket element 10 having a substantially circular shape from a first view (A) and a second view (B). The socket element 10 is for installation of an elec- trical socket or an air duct. The socket element 10 comprises along an insertion direction 40 a mounting aperture 12 connected to a flange 30. The flange 30 is connected to an insertion end 14. The flange 30 comprises a centrally-positioned flange aperture 32 and a flange face 34, which defines a flange plane 42 being perpendicular to the insertion direction 40. The flange face 34 has a plurality of structure gaps 36.

In this embodiment the insertion end 14 is a connection aperture 16 as the socket element 10 is adapted for an air duct.

Fig. 5 illustrates a side view of a socket element 10 comprising locking means 18. The locking means 18 enables the socket element 10 to hold a grating.

Fig. 6 illustrates a side view of a socket element 10 connected to an air duct 59 after installation in a wall 50. The socket element 10 is similar to the embodiment disclosed in Fig. 4.

The socket element 10 is installed into a wall 50. The wall 50 comprises a load- bearing structure 58, insulation 54 and plaster 56. The insulation 54 defines the wall face 52 on which plaster 54 and the flange is placed. An air duct 59 goes through the wall 50 and interlocks with the socket element 10. Plaster 56 has been provided on the wall face 52. In this way a stable and moisture tight connection is created between the socket element 10, the wall 50 and the air duct 59. Fig. 7 illustrates a socket element 10 comprising connection channels 201, 2011. The socket element 10 is shown in an upper sideways view (A) and a lower sideways view (B) and a top view (C). The socket element 10 comprising, along an insertion direction 40, a mounting aperture 12 connected to a flange 30. The flange is connected to an insertion end 14.

The flange 30 comprises a centrally positioned flange aperture 32 and a flange face 34 defining a flange plane 42. The flange plane 42 is perpendicular to the insertion direction 40. The flange face 34 has a plurality of structure gaps 36.

The plurality of the structure gaps 36 are elongated structure gaps as tests have shown that this improves the adhesiveness between the flange and plaster, when in intended use. The socket element 10 has a first connection channel 201 and second first connection channel 2011 positioned between the flange 30 and the insertion end 14. The connection channels 201, 2011 extending perpendicularly relative to the insertion direction 40.

The connection channels 201, 2011 are adapted for interlinking with another connec- tion channel 20 of another socket element 10 (not shown).

The flange 30 further comprises a first flange break line 381 and second flange break line 3811. The flange break lines 381, 3811 are arranged such that when part of the flange is broken then the corresponding connection channels 201, 2011 will be ex- posed, such that two connection channels 20 may interlink.

The flange break lines 381, 3811 are formed by three elongated structural gaps, which have a weakened structure between each other. The flange 30 has three flange regions divided by the flange break lines 381, 3811. The removable regions of the flange have elongated structure gaps which are mutually parallel and perpendicular to the flange region permanently attached to the socket element. Tests have shown that having elongated structure gaps which are mutually perpendicular result in a strong connection with plaster when in intended use.

Fig. 8 illustrates a side view of a socket element 10 comprising connection channels 201, 2011 before (A) and after (B) installation in a wall face 52.

The socket element 10 is shown in greater detail in fig. 7.

The wall 50 has a load-bearing structure 58 with a layer of insulation 54 which define the wall face 52. The wall 50 is an insulated facade system.

The socket element 10 is positioned in the insulation 54 such that the flange 30 is parallel with the insulation 54, i.e. the wall face 52.

Plaster 56 is arranged on the flange 30 and insulation 54 up to the mounting aperture 12.

Although not explicitly shown, the plaster 56 comprises a first layer of plaster and a second layer of plaster, where a reinforcement mesh is positioned between the first and second layer of plaster.

The skilled person would realise that the combination of the flange, plaster and reinforcement mesh enables the socket element to be installed in the insulation without use of screws, rods or the like. Thereby, the mounting element may be installed fast and easy, while maintaining a high load capacity.

Fig. 9 illustrates a method 100 of installing a socket element 10 in a wall 50.

The method 100 comprises one or more acts of;

an act of providing 110 a socket element 10;

an act of pre-carving 120 in the insulation 54 a hole complementary to the socket ele- ment 10;

an act of inserting 130 the socket element 10 into the hole; and

an act of applying 140 plaster on the flange 30 and the insulation 54.

The method may further comprise one or more acts of; an act of applying 140 a reinforcement mesh on the plaster 56; and an act of applying 140 plaster 56 on the reinforcement mesh.

Claims

1. A socket element (10) for installation of an electrical socket in insulation (54) of a wall (50), the socket element (10) comprising along an insertion direction (40) a mounting aperture (12) connected to a flange (30), which is connected to an insertion end (14), the flange (30) comprising a centrally-positioned flange aperture (32) and a flange face (34) defining a flange plane (42) being perpendicular to the insertion direction (40), the flange face (34) having a plurality of structure gaps (36).

2. The socket element (10) according to claim 1, characterised in that the flange (30) is thickest near the flange aperture (32) and thinnest near an outer periphery of the flange (30).

3. The socket element (10) according to one or more of the previous claims, characterised in that the socket element (10) is a monolith.

4. The socket element (10) according to one or more of the previous claims, characterised in that the socket element (10) is made of ABS.

5. The socket element (10) according to one or more of the previous claims, charac- terised in that the insertion end (14) comprises a connection aperture (16) for pulling a wire.

6. The socket element (10) according to one or more of the previous claims, characterised in that the socket element (10) comprises a connection channel (20) between the flange (30) and the insertion end (14), the connection channel (20) extending perpendicular relative to the insertion direction (40) and being adapted for interlinking with another connection channel (20) of another socket element (10).

7. The socket element (10) according to claim 6, characterised in that the flange (30) comprises a flange break line (38) arranged in the flange (30) above the connection channel (30).

8. The socket element (10) according to claims 6 or 7, characterised in that the socket element (10) comprises a second connection channel (20) positioned between the flange (30) and the insertion end (14), the second connection channel (20) extending perpendicular relative to the insertion direction (40) and being adapted for interlinking with another connection channel (20) of another socket element (10).

9. The socket element (10) according to claim 8, characterised in that the flange (30) comprises a second flange break line (38) arranged in the flange (30) above the second connection channel (20).

10. An insulated facade system comprising one or more socket elements (10) accord- ing to claim 1-9.

11. The insulated facade system according to claim 10, characterised in that the insulated facade system comprises one or more socket elements (10) according to claim 6-9 forming a socket system.

12. The insulated facade system according to claim 10 or 11, characterised in that the one or more socket elements (10) are positioned in insulation of the insulated facade system and the mounting aperture (12) faces away from the insulated facade system, and a first layer of plaster is arranged on the flange (30), a reinforcement mesh is arranged on the first layer of plaster and a second layer of plaster is arranged on the reinforcement mesh.

13. A method (100) for installing a socket element (10) in insulation (54) of a wall (50), the method (100) comprising one or more acts of;

an act of providing (110) a socket element (10) according to one or more of claims 1-

9;

an act of pre-carving (120) in insulation (54) a hole complementary to the socket element (10);

an act of inserting (130) the socket element (10) into the hole; and

an act of applying (140) plaster (56) on the flange (30) and the insulation (54).

14. The method (100) according to claim 10, wherein the method (100) comprises one or more acts of:

an act of applying (140) a reinforcement mesh on the plaster (56); and an act of applying (140) plaster (56) on the reinforcement mesh.

15. Use of a socket element (10) according to one or more of claims 1-9 for installing an electrical socket in insulation (54) of a wall (50).

16. Use of a socket element (10) according to one or more of claims 1-9 for installing an electrical socket in an insulated facade system.

17. Use of two or more socket elements (10) according to one or more of claims 6-9 for installing a socket system in an insulated facade system.