TECHNICAL FIELD

The present invention relates to an apparatus and system for retrieving a conduit (such as a flexible electrical conduit) from within a cavity formed behind a plasterboard wall or other structure.

BACKGROUND

The discussion of documents, acts, materials, devices, articles and the like is included in this specification solely for the purpose of providing a context for the present invention. It is not suggested or represented that any or all of these matters formed part of the prior art base or were common general knowledge in the field relevant to the present invention as it existed before the priority date of each claim of this application. Cavity walls are often formed by a plasterboard (also known as "gyprock", "drywall" and "sheetrock") affixed to a building frame. The plasterboard forms the interior of a room, with electrical outlets being mounted on the plasterboard and facing the room interior. Electrical conduit is often passed through cavity walls to connect electricity to a wall mounted outlet. The electrical conduit often extends from a location above the power outlet, generally from a ceiling region, and downwardly through the wall cavity, to connect to the power outlet.

In installing a power outlet, a hole is typically made in the plasterboard and a first person lowers the conduit from the ceiling and a second person hooks the conduit through the hole in the plasterboard. The hooked conduit is dragged through the hole and connected to the power outlet. The power outlet is subsequently mounted onto the plasterboard, over the hole.

A problem exists in that the person hooking the conduit is generally blind to the location of the conduit behind the plasterboard and needs guidance from the person in the ceiling, who is able to see the position of the conduit relative to the aperture. In some instances, because of poor lighting conditions, further difficulty is encountered even where one or both of the two persons has a line of sight to the conduit and/or hole.

It is an aspect of the present invention to overcome or ameliorate a problem of the prior art by proving an apparatus and system to facilitate the handling of conduit within a cavity wall. It is a further aspect to provide a commercially useful alternative to prior art means handling of conduit within a cavity wall. l INVENTION SUMMARY

In a first aspect, but not necessarily the broadest aspect, the present invention a conduit urging means comprising a unitary formed holding means and elongate flexible member, wherein the elongate flexible member is formed of a flexible curved region adapted to move between a closed condition, in which the elongate flexible member is able to pass through an aperture in a plasterboard, and an open condition in which the elongate flexible member is expanded in a space behind the plasterboard in order to receive a conduit lowered into the curved region, to thereby allow the conduit to be pulled back through the aperture when the conduit urging means is withdrawn through the plasterboard.

In one embodiment of the first aspect, the conduit urging means is formed of a polymer, and particularly a man-made polymer.

In one embodiment of the first aspect, the elongate flexible member is resilient and the open condition is the rest state of the elongate flexible member.

In one embodiment of the first aspect, the curved region comprises a main strip across a terminal region of the curved region, with sufficient rigidity to hold the curved region in the open condition, in the rest state.

In one embodiment of the first aspect, the urging means comprises directing means to ensure the elongate flexible member is located behind the plasterboard in the correct orientation relative to the hole to receive the conduit.

In one embodiment of the first aspect, the directing means is in the form of a profiled flange between the holding means and the elongate flexible member. In one embodiment of the first aspect, the flange has a rectangular or square cross-sectional shape. Alternatively, the flange has a circular cross-sectional shape and the directing means comprises one of a protruding member or receiving area associated with the flange.

In one embodiment of the first aspect, the conduit urging means comprises support means configured to support the conduit urging means in a desired position with reference to a wall into which the elongate flexible member extends. In one embodiment of the first aspect, the conduit urging means comprises a light source configured to direct light into a wall cavity into which the elongate flexible member extends.

In one embodiment of the first aspect, the elongate flexible member comprises or is coated with a light emitting compound.

In one embodiment of the first aspect, the conduit urging means comprises a lockable tension mechanism configured to, when unlocked, allow a user to pull outwardly a desired length of elongate flexible member, and when unlocked, allow the tension mechanism to pull the elongate flexible member inwardly.

In one embodiment of the first aspect, the lockable tension mechanism comprises a spool configured to retain and release a length of the elongate flexible member, and a biasing means, wherein the biasing means is configured to bias the spool toward a state whereby the majority of the elongate flexible member is retained on the spool.

In a second aspect, there is provided a receiving means for use with the above described conduit urging means, wherein the receiving means has engagement regions to fasten the receiving means over the hole in the plasterboard and a passage adapted to be located over the hole, to provide access to the space, the passage having an entry means with a flange engagement means to match the directing means of the conduit urging means.

In one embodiment of the second aspect, the flange engagement means comprises one of a protruding member or receiving area to fit with an associated one of a receiving area or protruding member of the conduit urging means directing means.

In an alternative embodiment of the second aspect, the flange engagement means has a rectangular or square cross-sectional shape to match with a corresponding cross-sectional shape of the conduit urging means directing means.

In one embodiment of the second aspect, the receiving means comprises a main plate, from which the passage projects, and a plurality of viewing ports arrayed around the passage to facilitate visual inspection into the space behind the plasterboard. A system may be formed by a combination of the first and second aspects. The system may be sold in unitary vendible packaging (such as in kit form), optionally with instructions for use. The present invention may also be in the form of a method for urging a conduit disposed within a cavity wall according to any one or more of the method steps described herein.

Also provided by the present invention is a conduit urging means or a receiving means as described herein and with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention is described, by way of non-limiting example only, with reference to the accompanying drawings, in which:

FIG. 1A is a drawing in isometric view of a conduit urging means in an open condition.

FIG. 1 B is a drawing isometric view of the conduit urging means of FIG. 1A from the reverse angle of the view of FIG. 1A.

FIG. 1 C is an end-on view of the conduit urging means of FIG. 1 B

FIG. 1 D is a schematic cutaway diagram in lateral view showing a ratchet-like mechanism for alternately locking and releasing a flexible elongate member of the conduit urging means.

FIG. 1 E is a schematic cutaway diagram in lateral view of a conduit urging means having a locking and spring tension mechanism.

FIG. 1 F is a schematic diagram showing in greater detail the spring tension mechanism of the conduit urging means of FIG. 1 E.

FIG. 1 G is a schematic diagram showing greater detail the junction between the spring tension winding and the conduit urging means of the spring tension mechanisms of FIG. 1 F. FIG. 2 is an isometric view of a conduit urging means in an open condition.

FIG. 3 is an isometric view of the conduit urging means in a closed condition and a receiving means mounted to a plasterboard; FIG. 4 is an isometric view of the conduit urging means installed in a space behind the plasterboard; FIG. 5 is an isometric view of the conduit urging means being withdrawn from the plasterboard, with a conduit;

FIG. 6 is a front isometric view of the receiving means; and

FIG. 7 is a rear isometric view of the receiving means.

DETAILED DESCRIPTION OF THE INVENTION AND BEST METHOD KNOWN BY THE APPLICANT FOR PRACTICING THE INVENTION

Reference throughout this specification to "one embodiment" or "an embodiment" means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases "in one embodiment" or "in an embodiment" in various places throughout this specification are not necessarily all referring to the same embodiment, but may. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner, as would be apparent to one of ordinary skill in the art from this disclosure, in one or more embodiments. Similarly it should be appreciated that the description of exemplary embodiments of the invention, various features of the invention are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure and aiding in the understanding of one or more of the various inventive aspects. This method of disclosure, however, is not to be interpreted as reflecting an intention that the claimed invention requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment. Thus, the claims following the Detailed Description are hereby expressly incorporated into this Detailed Description, with each claim standing on its own as a separate embodiment of this invention.

Furthermore, while some embodiments described herein include some but not other features included in other embodiments, combinations of features of different embodiments are meant to be within the scope of the invention, and from different embodiments, as would be understood by those in the art.

In the claims below and the description herein, any one of the terms "comprising", "comprised of" or "which comprises" is an open term that means including at least the elements/features that follow, but not excluding others. Thus, the term comprising, when used in the claims, should not be interpreted as being limitative to the means or elements or steps listed thereafter. For example, the scope of the expression a method comprising step A and step B should not be limited to methods consisting only of methods A and B. Any one of the terms "including" or "which includes" or "that includes" as used herein is also an open term that also means including at least the elements/features that follow the term, but not excluding others. Thus, "including" is synonymous with and means "comprising".

Furthermore, it is not represented that all embodiments display all advantages of the invention, although some may. Some embodiments may display only one or several of the advantages. Some embodiments may display none of the advantages referred to herein.

Reference is made firstly to FIG. 1A which shows several broad features of a preferred embodiment of a conduit urging means (100) of the invention. The conduit urging means (100) comprises a polymer formed unitary holding means (102) and an elongate flexible member (103) which in this embodiment a portion extends externally to the holding means (102) to form of a flexible resilient curved region which extends from, and returns back into the holding means (102). Some of the elongate flexible member (not shown) is retained inside the holding means (102).

The elongate flexible member (103) is shown in an expanded, open condition, which is the rest state of the external curved region. In that condition, a relatively large aperture (109) is defined. In use, the curved region is introduced into a wall space (via a hole made in plasterboard, not shown) such that the aperture (109) essentially conforms to the shape of the space. A portion of electrical conduit (not shown) is fed into the aperture (109) within the wall space. Withdrawal of the elongate flexible member (103) through the hole formed in the plasterboard causes the electrical conduit to be drawn through that same hole, and therefore outside the wall. Once the conduit is brought external to the wall, it can be connected to a power outlet or indeed used for any other purpose.

Referring now to FIG. 1 B there is shown the embodiment of FIG. 1 , but viewed in the reverse direction to show a support means (150) which is configured to engage with the edge of plasterboard formed by the cutting of a hole in the plasterboard. It will be noted that the support member has a horizontal portion extending form the face (152) of the holding means (102) and a vertical portion extending downwardly from the horizontal portion. Thus, the face (152) and support means (150) combine to form a downwardly-directed U-shaped channel which is dimensioned so as to snugly engage with a portion of plasterboard surrounding the hole made in the plasterboard. When the support means (150) is snugly engaged with the plasterboard, the holding means (102) may be let go by a user, and the conduit urging means (100) will remain in place on the plasterboard edge. Accordingly, the elongate flexible member (103) and aperture (109) formed thereby stay in position within the wall space ready to accept an electrical conduit being passed through the space.

Alternatively, the support means (150) may be configured and dimensioned to engage with a receiving means engaged with the plasterboard wall, as discussed in more detail infra. In this embodiment, the support means may assume a completely different shape and dimension as to that shown in FIG. 1 B, and may be complementary to a formation on the receiving means.

Advantageously, this embodiment may allow for a single person to (i) set up the conduit urging means, (ii) move into the ceiling space, (iii) pass the conduit downwardly from the ceiling into the space and through the aperture (109), and (iv) return to floor level and pull the conduit through the hole formed in the plasterboard wall.

Referring now to FIG. 1 C there is shown a partial end-on view of the conduit urging means (100) shown in FIGS. 1A and 1 B. This view shows a light source (154) (preferably being light emitting diodes) housed in the holding means (102) in operable connection with a battery (not shown). In use, the light source (154) directs light into the space of the cavity wall to assist a person to see the location of any one of (i) the hole in the plasterboard, (ii) the elongate flexible member (103), the aperture (109) or electrical conduit.

Although not apparent from the drawings, the elongate flexible member (103) is fabricated from a polymeric material impregnated with a phosphor compound such as zinc sulphide or strontium aluminate. Accordingly, the phosphor absorbs ambient light before the elongate flexible member (103) is inserted into the wall space, and then emits that light (typically as a green-tinted light) into the darkness of the wall cavity when inserted therein. A person looking into the darkness of the wall space will be more readily able to visualize the position of the elongate flexible member (103) and therefore also the aperture (109).

The improved visibility of the various components may assist either a person at floor level (receiving the conduit) or a person in a ceiling (feeding the conduit) in the task of guiding the conduit through the aperture (109). This advantage may be especially important where only a single person is involved. In the embodiment of FIGS. 1A, 1 B and 1 C the elongate flexible member is adjustable in length so as to allow a user to set the length of the member which extends away from the face (152). Where a wall space is relatively small (possibly because of two proximal wall spacer members, or "studs") then a relatively short length is set. This is achieved by pushing the member (103) back through the face (152) and into the holding means (102). Having the length set too long in this circumstance will cause the flexible elongate member (103) to bunch up, with regions of member (103) extending inwardly and toward the centre of the aperture (109). These inwardly extending regions interfere with the clear passage of conduit through the aperture (109).

Where a wall space is relatively large (possibly because there are no proximal wall spacer members) then the flexible elongate member is set to a relatively long length. This is achieved by pulling a further length of the member (103) from within the holding means (102) through the face (152). Having the length set too short in this circumstance will mean that the elongate flexible member will tend not to occupy the full depth of the wall space. Instead, a space is formed between an external surface of the elongate flexible member (103) and an internal surface of the wall cavity. There is a likelihood in that situation that the conduit will not pass through the aperture and therefore not caught by the conduit urging means (100).

Altering the length of the flexible elongate member (103) extending beyond the face (152) may be facilitated by a ratchet-like arrangement. As shown in FIG. 1 D, a surface of the member (103) may have a series of teeth (160) extending therefrom. Within the holding means is a spring-loaded pawl (162). The shapes of the teeth (160) and pawl (162) allow for movement of the member (103) in only one direction (to the right, as drawn) when the pawl is biased downwardly as shown in the drawing. Thus, the member (103) can be manually pulled so as to lengthen it, and once the required length is achieved the member is prevented from being shorted by the pawl (162) which (where the member (103) is moved to the left, as drawn) will lock against the opposed tooth (160). When the user desires to shorted the flexible elongate member (103), a button (164) is depressed by the user causing the pawl (162) to assume an elevated position and allowing the member (103) to move toward the left (as drawn). The button (164) is biased so as to return the pawl (162) to the lower (locking) position upon release by the user. As will be noted, the holding means (102) has an opening (166) (shown at FIG. 1A) at its terminus to allow for any part of retracted flexible elongate member (103) to extend therethrough if necessary. Reference is now made to FIG. 1 E which shows a further preferred conduit urging means (200) of the invention having a spring tension mechanism (202) operably connected to an elongate flexible member (204). It will be noted that the elongate flexible member (204) is secured at one end (206) to the interior wall of the holding means (208). The elongate flexible member extends into the hollow of the holding means (208), and passing over a guide surface (210) and the downwardly toward the spring tension mechanism (202) where it is taken up in a spool-like manner. A user-operable locking mechanism is presented in the form of a bi- positional mechanical rocker switch (212) seated in the wall of the holding means (208). The switch (212) has a wedging portion (214) which, when the switch is in the locking position (as drawn), inserts between (i) the lower face of the portion of the elongate flexible member (204) extending downwardly and into the tension mechanism (202), and (ii) the upper face of the portion of the elongate flexible member (202) that is spooled onto the tension mechanism (202). In the locked position, the wedging portion (214) acts to prevent spooling and unspooling of the elongate flexible member (204) onto and off the tension mechanism (202), thereby maintaining the elongate flexible member (204) at a fixed length.

In use, the switch (212) is initially in the unlocked state and the elongate flexible member (204) is pulled outwardly by the user to a length sufficient to just occupy a wall cavity. The tensioning mechanism is biased against the outward pulling motion, as will be described more fully infra. Once the required length of elongate flexible member (204) is achieved, the switch (212) is moved by the user to the locked state. Thus, the user is able to leave the conduit urging device (200) unattended and may, for example, move to a ceiling region of the building in order to feed electrical conduit (not shown) downwardly through the wall cavity so as to pass through the aperture (216) formed by the elongate flexible member (204).

When the conduit has been successfully pulled through a wall opening, the conduit urging means (200) has no immediate use. The switch (212) is moved by the user to the unlocked position, with the biasing function of the tension mechanism (202) acting to retract unspooled elongate flexible member (204) onto the spool of the tension mechanism. In this way, the conduit urging means (200) becomes compact and easy to store. The elongate flexible member (204) is ready to be pulled outwardly again by the user in the next job. The tension means (202) is shown in greater detail in FIG. 1 F to comprise principally of a spool (218) having a metal spiral torsional spring winding (220) secured at a first end (222) to a slot (224) in the spool (218). The second end (226) of the winding is connected to the free end (228) of the elongate flexible member (204). Thus, the bias of the winding (220) tends to rotate the spool (218) in an anti-clockwise (as drawn) direction, thereby pulling the elongate flexible member onto the spool. The winding (220) is not sufficiently strongly biased so as to make difficult a user pulling elongate flexible member (204) off the spool (218).

The means for connecting to the winding (220) to elongate flexible member (204) is shown in FIG. 1 G. The terminal region of the elongate flexible member (204) comprises a triangular aperture (230). The terminal region of the winding (220) is formed in a T-shaped portion (238). In assembly, the T-shaped portion is orientated such as the arms of the "T" are orthogonal to the plane of the elongate flexible member (204) and in that orientation are passed through the aperture (230). Once through the aperture (230) the arms of the "T" are rotated so as to be parallel to the plane of the elongate flexible member (204) and to sit under the elongate flexible member (204), as shown in FIG. 1 G.

Referring back now to FIG. 1 E, this embodiment further comprises an LED light source (232). Furthermore, a small saw blade (234) in stored in the cavity of the holding means (208). The saw handle (236) screws into the base of the holding means (208), so as to conveniently store the saw (234, 236). In use, the saw (234, 236) is used to cut an opening into a plasterboard wall, the opening being required to mount a power outlet for example.

A further preferred embodiment of a conduit urging means 1 is shown in FIG. 2. The conduit urging means (1) comprises a polymer-formed unitary holding means (2) and an elongate flexible member (3). The elongate flexible member (3) is formed of a flexible resilient curved region (4) that has a main strip (5) across a terminal region (6) of the curved region (4), two side strips (7) and joining regions (8) to couple the curved region (4) back into the holding means (2).

The elongate flexible member (3) is shown in an expanded, open condition, which is the rest state of the curved region (4). In that condition, the main strip (5) has sufficient rigidity to adopt a relatively straight position so that the side strips (7) are curved and displaced laterally, in order to define an aperture (9). Directing means (10) is provided on a flange (11), between the holding means (2) and the elongate flexible member (3). The directing means (10) has a substantially rectangular or square shaped engagement means (12) which may be used to orientate the curved region (4). Referring to FIG. 3, a section of wall (13) is diagrammatically illustrated as having a facing surface (14) that covers a space (15) behind the plasterboard (13), in between two plasterboard spacing members (16). A posterior panel (17) closes the space (15). A hole (18) is formed in the plasterboard (13) at a location where a power outlet (not shown) is to be mounted.

A receiving means (19) is attached over the hole (18) using engagement regions (20). The receiving means (19) has a passage (21) that projects from a bottom plate (22) of receiving means (19). The receiving means (19) provides access into the space (15), through the passage (21).

The conduit urging means (1) is shown in a closed condition, where the main strip (5) has been folded to collapse the side strips (7) together. In that condition, the conduit urging means (1) is presented to the receiving means (19), for insertion into the space (15) behind the plasterboard (13).

Referring to FIG. 4, the conduit urging means (1) has been pushed through the receiving means (19), to a position where the directing means is engaged in an entry means (23) of the receiving means (19). The flange (11) is in this instance circular in cross section. The entry means (23) has a flange engagement means (24) to engage the circular flange (1 1). In this case, the directing means (10) is in the form of a series of circumferential protruding members (25) that are received in receiving area (26) that define the flange engagement means (24) of the receiving means (19).

Alternatively, the entry means (23) may be formed with protruding members and the directing means (10) may be in the form of associated matching receiving areas.

The flange engagement means (24) of the entry means (23) allows the curved region (4) to be oriented cross-wise between the spacing members (16) so that the aperture (9) is appropriately located to extend across the space (15).

The flange engagement means (24) of the entry means (23) in one embodiment allows for the flange (11) to slot into the passage (21) at 90 degree intervals so that the curved region (4) can adopt the same position behind the plasterboard (13), irrespective of whether the receiving means (19) is fixed over the hole (18) in either a vertical or horizontal position. Referring now to FIG. 5, the conduit urging means (1) is shown partially withdrawn from the plasterboard 13, with a conduit (27) captured in the elongate flexible member (3). As may be appreciated, the conduit (27) has been lowered down into the space (15) behind the plasterboard (13) and through the aperture (9), shown in FIG. 3.

From that position, the conduit urging means (1) has been retracted through the receiving means (19), to cause the elongate flexible member (3) to close around the conduit (27), in order to allow the conduit (27) to be retrieved from the space (15) and pulled out from behind the plasterboard (13). Once the conduit (27) is pulled through the plasterboard (13), the receiving means (19) is removed to allow the conduit (27) to be connected to a power outlet (not shown), which is then fitted over the hole (18).

The conduit urging means (1) of FIG. 4 is the same as that shown in FIG. 1 , with a square shaped flange (1 1). As such, the receiving means (19) illustrated in FIG. 4 has a rectangular or square shaped entry means (23) to match the external cross-sectional shape of the flange (1 1).

The square shape of the entry means (23) is more clearly illustrated in FIG. 7, where the flange engagement means (24) is in the form of a square opening (28) inside the square shaped passage (21). The receiving means (19) is also shown as comprising a plurality of viewing ports (29) arrayed between the engagement regions (20) and around the passage (21). The viewing ports (29) allow visual inspection into the space (15) from above, below or to the side of the passage (21). Visual inspection may be used to confirm the conduit (27) is in fact within the curved region (4) of the conduit urging means (1), before the conduit urging means (1) is withdrawn from the space (15).

Referring now to FIG. 7, a rear view of the receiving means (19) is shown, where a rear side (30) of the entry means (23) has tapered inclined planes (31) located at 90 degrees. The inclined planes (31) serve as an additional alignment mechanism. When the conduit urging means (1), as shown in FIG. 1 , is fully inserted in the receiving means (19), the joining regions (8) rest in the associated inclined planes (31) to ensure the curved region (4) is maintained in an orientation cross-wise of the space (15). As the conduit urging means (1) is withdrawn from the space (15), the inclined planes (31) successively engage the associated strips (5), (7) of the conduit urging means (1), to maintain correct alignment.

As may be appreciated from the above, since the holding means (2) and elongate flexible member (3) are formed of a polymer material, the conduit urging means (1) can be formed as a unitary item by a molding process, to allow the conduit urging means (1) to be cheaply and easily produced. It is also ideal for the conduit urging means (1) to be made from a polymeric material, in order to provide electrical insulation properties important in the handling of electrical conduits.

It should also be appreciated the invention has been described by reference to use in retrieving electrical conduits from within a plasterboard wall cavity. However, the invention also has application to retrieving other forms of cabling or conduits, as required.