AU2004299520B2 - Fence construction systems - Google Patents

Description

WO 2005/059279 PCTiAU20041001791 -1- FENCE CONSTRUCTION SYSTEMS BACKGROUND TO THE INVENTION This invention relates to construction of fences, in particular but not only to systems for construction of pool fences or balustrades. The systems might also be suitable for other structures which in some cases have picket-like features in common with fences, such as ladders or walls.

Pool fences are constructed in a wide variety of ways. A standard pool fence typically has a number of aluminium panels that are formed separately and then placed in position together. Each panel has two or more horizontal rails that support a series of vertical pickets. The panels are assembled by passing the pickets through apertures in the rails.

Each picket is then usually welded or crimped to the rails and the assembled structure is painted. The rails and pickets come in many forms and may be assembled in a wide variety of structures.

The existing methods of construction require each picket to be individually handled and fastened to the rails. Each panel typically has 20-30 pickets so the methods are generally slow with a significant cost of manual labour. The need to paint the panel after the pickets have been fastened to the rails can also be a disadvantage. Structural weaknesses are sometimes experienced in panels where the pickets do not extend beyond the top rail. In these systems the top ends of the pickets lie within the top rail and can be difficult to fasten sufficiently strongly to the rail.

SUMMARY OF THE INVENTION It is an object of the invention to provide for improved construction of pool fences, or at least to provide an alternative to existing systems.

0 Opv'&LCU7007%Mc 200rAI2553250 W pae ainmp Sp s=w. cI.,nS 86dm-27hV3I2 -2- In one aspect the invention resides in a panel for a fence, having at least one hollow rail and a plurality of pickets supported by the rail, wherein the pickets enter the rail by passage through respective entry apertures in the rail, and a portion of each picket located inside the rail is deformed to thereby prevent further passage of the pickets through their respective entry apertures.

In a further aspect the invention resides in a panel for a fence, having at least one hollow rail and a plurality of pickets supported by the rail, wherein the rail has an external wall with entry apertures for the pickets, and an internal wall for holding end portions of the pickets, and wherein each picket enters the rail through a respective entry aperture and has an end portion which is held by a corresponding holding aperture in the internal wall.

In a further aspect the invention resides in a method of forming a picket structure, such as a fence panel, including: providing a hollow rail to support a plurality of pickets, passing each picket at least partly through the rail, and fastening the pickets to the rail by movement of a fastening tool through the rail.

In another aspect the invention resides apparatus for forming a picket structure, such as a fence panel, including: a frame for supporting two or more rails of the structure in position to receive pickets, a fastening tool mounted on the frame in alignment or for alignment with the rails, and a tool driver that drives the fastening tool through the rails to fasten the pickets to the rails from within the rails.

In another aspect the invention resides in a picket structure having a rail and a plurality of pickets supported by the rail, each picket being fastened to the rail by fastening means including a deformation of the picket located within the rail.

The picket structure may be a fence or balustrade, or a similar arrangement having rail and picket features, such as a ladder. In the case of a structure having a pair of rails, the pickets are typically fastened within each rail.

QA\Op& ALCU2W7V\. 2007\I 2S532S0 s p.mel p s pw. clans 86do.27)Y2007 -3- LIST OF FIGURES Preferred embodiments of the invention will be described with respect to the accompanying drawings, of which: Figure 1 shows components of a panel for a pool fence, IFigure 2 shows an assembled panel having pickets held by three rails, Figure 2 shows an assembled panel having pickets held by twohree rails, ~Figure 3 shows an assembled panel having pickets held by two rails, Figure 4 shows one way of fixing the pickets within the rails using a locking rod, Figure 5 shows another way of fixing the pickets within the rails by crimping, Figure 6 shows how a top rail structure may be strengthened, Figure 7 shows how the structure in Figure 6 may be used in a raked panel, Figure 8 shows the structure and operation of equipment that may be used to fix the pickets in the rails, Figure 9 shows various crimping components for the equipment in Figure 8, Figure 10 shows an alternative component for the equipment in Figure 8, and Figure 11 shows alternative equipment.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS Referring to the drawings it will be appreciated that the invention can be implemented in various ways for a range of different picket-like structures, such as pool fences, balustrades, ladders, walls and the like. This description of pool fence embodiments is given by way of example only.

Figure 1 shows the main components of a panel for a pool fence including a bottom rail mid rail 11, a top rail 12, a number of pickets 13, two posts 14, locking rods 15 and top pins 16, and bottom pins 17. These components may be provided in a wide range of numbers, shapes, and sizes, and may be assembled in different ways, depending on the purpose and style of the fence. The components are usually provided has hollow tubes or other sections of a metal such as aluminium or steel.

Q Op6A'LCU0D7\lh l.c 2007\I553250u pnl cnmp nm s per. clans 86 doc.27MY000 -4- Figure 2 shows how the panel may be assembled. The pickets 13 pass through pairs of apertures in the bottom and mid rails 10, 11 and in this example, enter but do not exit the top rail 12, which has apertures on one side only. The rails are fixed in apertures in the posts 14 using the bottom and top pins 16, 17. Traditionally the pickets are fastened to the rails by external welding or crimping. In this case the pickets are fastened by internal means, such as the locking rods 15 which thread the pickets, or by internal crimping.

Figure 3 shows part of a panel of another fence having bottom and mid rails 30, 31 only, and again by way of example. The pickets 32 pass through apertures in each rail and are fastened to the rails. Only a single post 33 is shown. It will be appreciated that the panels may be formed in a wide variety of styles, shapes and sizes, with large or small numbers of pickets.

Figures 4a and 4b show two ways of fastening a picket to a rail from within the rail, using a locking rod, such as rod 15 in Figure 1. In Figure 4a, a top rail 40 and one end of a picket 41 are shown in cross section. The picket passes through an aperture on the underside 43 of the rail. A locking rod 42 passes through an aperture in the picket, located inside the rail, and deforms the underside of the rail. The aperture in the picket partly overlaps with the aperture in the rail. Manual or machine generated force is required to insert the rod and causes the deformation. The rod threads all of the pickets in the panel.

Figure 4b shows an alternative in which the inside of the rail includes a guide 45 for the locking rod 42. The guide may be continuous within the rail or interrupted by transverse apertures for the pickets, depending on the width of the guide. Apertures in the pickets are aligned with the guide as indicated. In both Figures 4a and 4b the pickets are shown as ending within a top rail, but may also pass through the rail as in a bottom or mid rail.

Figure 5 shows another way of fastening a picket within a rail to form a panel or other structure. In this example, bottom rail 50 and top rail 51 hold the picket 52. The picket has been deformed in portions 53 and 54 within each rail, by crimping for example. A typically Q %Opr\ALCM7\? 2A7\)2553250 pce m.p rpu mpj. 86do.-27rnT20C7 circular picket is deformed into a relatively flattened cross section within the rails and this prevents removal of the picket from either rail and securely fastens the picket into a panel.

Figure 6 shows an enhancement of Figure 5. In this example, top rail 60 now includes a support structure 61 which engages one end of the picket 62 to strengthen the panel once assembled. A portion of the picket has been crimped between within rail and below the support structure. Bottom rail 63 functions as before. In Figure 6b the support structure is indicated as a plate 65 with a series of apertures. In Figure 6c the support structure is a hollow section with a series of apertures or a continuous flange within the rail. In Figure 6d the plate in Figure 6b is held by fixtures on the in side walls of the rail. In Figure 6e, the support structure is adapted for a bottom rail or mid rail 68 and allows the pickets to pass through the rail. It will be appreciated that a wide range of internal structures are possible for the same or similar effect.

Figure 7 shows how the enhancement may assist with a raked panel such as required in a bannister. In Figure 7a the rails 70 are not perpendicular to the pickets 71, and the pickets pass only partially through both the top and bottom rails. Posts 73 are generally parallel to the pickets. As shown in Figure 7b this may require a support structure 74 similar to that in Figure 6a, but enabling the apertures for the pickets to be offset within the rail. The structure may be slidable within the rail to assist assembly and installation of the panel on site. Figures 7c and 7d show how a slidable plate 75 or flange 76 may be formed within the rail. Note that the apertures in the support structure may be elongated in the case of circular pickets to accommodate the angular deviation.

Figure 8 schematically shows equipment for crimping a series of pickets inside a set of rails to form a panel. In Figure 8a the equipment includes a frame having a first portion for holding a pair of rails to form a panel and a second portion 81 for holding a crimping device that passes through the rails. The rails lie in brackets 82 on frame portion 80 while the crimping device has two separate tools 83 that are aligned with the brackets 82. Each tool is fixed at one end to a moveable carrier 84 by a bracket 85 and passes through a second bracket 86 at the other end for alignment with a respective rail, shown in further Q Op %LC500l74r0 250711251250 w panel cinp ner spec. clims 86doc-27)l 007 -6detail in Figure 8b. In this example, bracket 86 includes two plates 87 and a series of pins 88 which define a path for the tools 83.

In Figure 8a, a pair of chains 90 drive the carrier 84 back and forth in the frame portion 81 which in turn drives the tools 83 of the crimping device back and forth through the brackets 86. The chains rotate in a two-part cycle around axles 91 driven by a motor 92.

Leaf springs 93 mounted on frame 81 provide tension in the chain and accommodate variations in the motion caused by the action of tools 83 when crimping pickets in a panel.

It will be appreciated that different panel structures will require different arrangements of the brackets 82 and that in general a wide variety of equipment is conceivable as alternatives to the frame structure and components shown here.

Figures 8b to 8g show the equipment of Figure 8a in action to produce a simple panel. In Figure 8c a pair of rails 95 have been placed in brackets 82, in alignment with the tools 83 of the crimping device. The carrier is at the start of a cycle. In Figure 8d the carrier 84 has moved from right to left in frame 81 pushing the tools 83 into their respective rails and has reached half way in the cycle. In Figure 8e a series of pickets 96 have been inserted through the rails with the rods 83 held stationary. In Figure 8f the carrier has moved back through the frame 81 pulling the tools through the rails and crimping the pickets inside the rails, to complete the cycle. The complete panel is removed in Figure 8g.

Figure 9 schematically shows action of a crimping tool in Figure 8. In Figure 9a, a tool 100 is positioned then pulled through a rail 101 containing series of pickets 102, seen from above in cross section. In this example the tool includes two parallel elongate rods or bars, having opposed and thickened end portions 103. The end portions of the bars remain together and sequentially compress the portions of the pickets within the rail. In this case the tool is passed into the rail before insertion of the pickets. Figure 9b shows alternative crimping tools, including bars having rounded wedge portions 105, stepped wedge portions 106, and a roller assisted wedge portion 107.

Q *operALCUUMo7Muh 2007\1253250 u panl crip new p cl a 86 doc.271A03t207 -7- SFigure 10 shows a further alternative crimping tool intended for rapid processing of an assembled panel in which the pickets are already located in the rails. In Figure 10a the tool includes a bar 110 with a wedge 111 mounted on an arm 112. A slider 113 is also mounted on the arm 112 and is able to move back and forth in relation to the wedge. The N 5 arm passes through an aperture 114 in the slider. An inclined surface 115 assists the slider to move onto the wedge. The slider and the wedge are formed from a relatively rigid or dense material such as hardened steel.

In Figure 10b the slider 113 is aligned with the bar 110 as the tool is inserted in a rail 118 containing pickets 119. The slider is within the width of the bar and passes the pickets without crimping. As the tool is withdrawn the slider relocates onto the wedge and is deflected out of alignment with the bar. The slider effectively extends beyond the width of the bar thereby contacting and deforming the pickets within the rail as the bar is withdrawn. It will be appreciated that a variety of different tools having an action of this general kind can be designed.

Figure 11 shows further equipment as an alternative to the equipment in Figure 8, and could be used with the crimping tools of either Figure 9 or 10. The equipment includes a frame having a first portion 110 for holding one or more rails to form a panel and a second portion 111 for holding a crimping tool that passes through the rails. In this example, two rails would be placed in brackets 112 on frame portion 110, aligned with two rods 113 that pass through brackets 114, similar to Figure 8b. Each rod is fixed at one end to a moveable carrier 115 which is driven back and forth between the frame portions by a ram 116, and held in place on portion 111 by sleeves 118. The ram is in turn driven by a motor or pump 117 under automatic or manual control.

Claims (17)

1. 2. A panel according to claim 1 wherein the portion of each picket that has been deformed within the rail has a partly flattened shape that no longer matches the shape of the respective entry aperture in the rail.
2. 3. A panel according to claim 1 wherein the pickets pass though only one side of the rail and end at an internal wall within the rail, end portions of the pickets being held in respective apertures of the internal wall.
3. 4. A panel for a fence, having at least one hollow rail and a plurality of pickets supported by the rail, wherein the rail has an external wall with entry apertures for the pickets, and an internal wall for holding end portions of the pickets, and wherein each picket enters the rail through a respective entry aperture and has an end portion which is held by a corresponding holding aperture in the internal wall. A panel according to claim 4 wherein the holding apertures are aligned with the entry apertures so that the pickets are perpendicular to the rail.
4. 6. A panel according to claim 4 wherein the holding apertures are offset from the entry apertures so that the pickets are not perpendicular to the rail.
5. 7. A panel according to claim 4 wherein the internal structure is moveable within the rail to vary the alignment of the holding apertures and the entry apertures. 0 'OpcaLCU2GY74arch 200 22553250 .u pacl mnmp ns .pw. claims &6d-27131207 -9-
6. 8. A panel according to claim 4 wherein the holding apertures are formed by a plurality of flanges which receive end portions of respective pickets.
7. 9. A panel according to claim 4 wherein the pickets are fastened to the rail by a deformed portion of each picket within the rail. A method of forming a picket structure, including: providing a hollow rail to support a plurality of pickets, passing each picket at least partly through the rail, and fastening the pickets to the rail by movement of a fastening tool through the rail.
8. 11. A method according to claim 10 including providing a pair of hollow rails to support the pickets, passing each picket entirely through at least one of the rails, and fastening the pickets to the rails from within the rails.
9. 12. A method according to claim 10 including passing the fastening tool longitudinally one way through the rail before passing the pickets laterally through the rail, and then drawing the tool back through the rail to fasten the pickets from within the rail.
10. 13. A method according to claim 10 further including passing the pickets laterally through the rail and then passing the fastening tool longitudinally back and forth through the rail to fasten the pickets from within the rail.
11. 14. A method according to claim 10 wherein the fastening tool is a crimping tool which deforms the pickets within the rail. Apparatus for forming a picket structure, including: a frame for supporting two or more rails of the structure in position to receive pickets, a fastening tool mounted on the frame in alignment or for alignment with the rails, and a tool driver that drives the fastening tool through the rails to fasten the pickets to the rails from within the rails. Q AOpAALCU007IM.h 2007\1 2553250 au prcI cimp ncw spei clains 96 doc.27O3/2DO7
12. 16. Apparatus according to claim 15 wherein the frame supports a panel having two parallel rails and the fastening tool has two parallel deforming rods aligned with the rails.
13. 17. Apparatus according to claim 16 wherein each rod of the fastening tool has an expanded end portion that crimps the pickets within the rail.
14. 18. Apparatus according to claim 15 wherein the driver pushes the tool through the rails before the pickets are placed in the rails and then pulls the tool back through the rails to fasten the pickets in place.
15. 19. Apparatus according to claim 15 wherein the driver pushes and pulls the tool into and out of the rails after the pickets are in place. A picket structure having a rail and a plurality of pickets supported by the rail, each picket being fastened to the rail by fastening means including a deformation of the picket located within the rail.
16. 21. A picket structure according to claim 20 being a fence panel, a fence, a balustrade or a ladder.
17. 22. A picket structure according to claim 20 having a pair of parallel rails with the pickets being fastened to the rails by respective deformations within the rails.