AU2013200933A1 - A Wall or Fence System - Google Patents

Abstract

The present invention provides a post element having at least three sides, a first side being a joining side to join to a like sided element to create a post, a second side and a third side forming a panel receiving opening.

Description

1 A WALL OR FENCE SYSTEM Field of the invention [001] The present invention relates to a wall or fence system including a post element and a composite post and panel made from the element and a method of assembly of a wall or fence system as well as a fence system or wall system per se. Background of the invention [002] There are many differing and varied fence systems on the market and there is a need for a more efficient system that provides a solid appearance that can replicate the look of a masonry wall with superior sound attenuation current fence solutions, in particular one which can decrease the amount of inventory held by hardware retailers and hardware wholesalers. [003] Any reference herein to known prior art does not, unless the contrary indication appears, constitute an admission that such prior art is commonly known by those skilled in the art to which the invention relates, at the priority date of this application. Summary of the invention [004] The present invention provides a post element having at least three sides, a first side being a joining side to join to a like sided element to create a post, a second side and a third side forming a panel receiving opening. [005] The post element can be manufactured by rolling, pressing or extruding. [006] The post element can be formed whereby panel receiving opening is narrower than the panel to be inserted therein, creating a friction fit [007] The post element can be manufactured from a powder coated or zinc coated steel sheet material or aluminium [008] The panel receiving opening can include an inwardly extending sides on either side thereof. [009] A post for a fencing system being made from a post element as described above where two post elements are arranged so that their joining faces lie adjacent to each other.

2 [010] The joining faces can be secured together by means of one or more of the following:, self drilling screws, a bolt, bolts, cold working, apertures in the joining sides being tied, or other appropriate means. [011] The two elements can be arranged so that the panel receiving openings lie generally on a straight line. [012] The two panel openings can be arranged so as to lie at 90 degrees in the post. [013] The present invention also provides a method of assembling a post, the method including the step of arranging a post element as described above so that the first sides are adjacent each other, or a first side of one element is adjacent a second side of another element; and affixing the adjacent sides together. [014] The affixing can be done at one or more of the following locations near the top; near the top and bottom; one location between top and bottom; multiple locations between top and bottom. [015] The present invention further provides a method of constructing a fence utilising a post element or post as claimed in any one of the preceding claims wherein a panel supporting bracket which includes a portion having a width to provide sufficient clearance for a panel to be inserted in the panel receiving opening. [016] The bracket can be inserted into the panel receiving opening and rotated to expand the panel receiving opening to a width of a panel to be received therein; or the bracket is pushed into the panel receiving opening engaging angled flanges which act as inclined planes so that the opening is widened as the bracket is pushed therein. [017] The method can also include the step of securing the bracket to either side of the panel receiving opening by means of an axial pin joiner such as a rivet or a self-drilling and self tapping screw. [018] The method can include constructing the panel from two outer layers of fibre cement or magnesium board panel and a core of a polymeric material such as EPS, polystyrene or other appropriate material. [019] The present invention also provides a method of assembling a fence or wall including the steps of: 3 [020] (a) joining two post elements, as claimed in any one of the preceding claims together to form a 180 or 90 degree post element for the receiving of panels at 180 or 90 degrees with respect to each other: [021] (b) positioning a bracket in a panel receiving opening to expand the panel receiving opening to an appropriate width; [022] (c) securing the bracket to the element; [023] (b) Inserting a panel in the panel receiving opening between two post elements. [024] The methods described above can include the step of a post cap being placed upon the post, and or an end cap can be placed upon the top layer of the panel. [025] A post element as described above where the second side is a planar side. [026] The present invention further provides a fence system including post elements and panel elements wherein the post elements are of a predetermined length which is marginally larger than the length of the panels to be assembled with the post, the posts including panel receiving openings in one side of the post elements. [027] The system can include a spacing element of the same length as the posts and which is of a side dimension which is smaller than the panel receiving openings, so that the post can be inserted into the panel receiving openings whereby a post element can be used as a spacer for an assembler to space the posts to receive a panel during assembly. [028] The spacing element can be one of: a post; a decorative member; a strengthening member, or a combination of these. Brief description of the drawings [029] An embodiment or embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which: [030] Figure 1 is a perspective view of a post element; [031] Figure 2 is a mid post made from two post elements placed back to back; [032] Figure 3 illustrates a perspective view of a bracket in use with the post element and posts illustrated in figures 1 and 2; 4 [033] Figure 4 illustrates a front view of the bracket and post of figure 3; [034] Figure 5 illustrates perspective view of the bracket; [035] Figure 6 illustrates side view of the bracket and post of figure 3, with the post having a like post back to back; [036] Figure 7 illustrates the post of Figure 1 with a panel mounted therein; [037] Figure 8 illustrates the mid-post of Figure 2 with panels mounted therein; [038] Figure 9 is a perspective view of a composite post assembly made from two posts of figure 1 back to back with a square hollow section post; [039] Figure 10 illustrates a perspective view of a composite post assembly made from two posts of figure 1 placed back to side; [040] Figure 11 illustrates a wall or fence assembled from two assembled panels; [041] Figure 12 illustrates a wall or fence made from three assembled panels; [042] Figure 13 illustrates a side elevation of the footing of a post; [043] Figure 14 illustrates a plan view of the wall or fence arrangement of Figures 11 and 12; [044] Figure 15 illustrates a post and use with a length of strengthening member or a decorative member to establish correct post spacing from another post; [045] Figure 16 is a cross section of the strengthening member or a decorative member of figure 15; [046] Figure 17 illustrates the use of the strengthening member or a decorative member in its decorative role of closing the open post of figure 1; [047] Figure 18 illustrates a perspective view of a predetermined length of strengthening member or a decorative member; [048] Figure 19 illustrate the strengthening member or a decorative member temporarily in position between two posts (supported vertically by the brackets) so that the posts are at the correct spacing. This member also provides a horizontal surface to place a spirit level on to obtain correct vertical alignment for consecutive posts.

5 [049] Figure 20 illustrates in perspective view the strengthening member or a decorative member in use with a post; This is commonly used to conceal the panel opening at the start or end of a wall or when the wall is 'stepped' to conceal the panel opening where the panel will not finish flush with the top of the post. [050] Figure 21 illustrates a composite corner post assembly where panels will only enter on two sides showing use of the strengthening member or a decorative member to close the other unused open side of said post. [051] Figures 22 to 26 illustrate respectively the plan views of the post of figures 1, 2, 21, 9 and 10. [052] Figure 27 illustrates a cross-section or plan view of an in-fill member. [053] Figure 28 illustrates a cross-section or plan view of a post or post element. [054] Figure 29 illustrates a cross-section or plan view of the members of figures 27 and 28 assembled together. Detailed description of the embodiment or embodiments [055] Illustrated in Figure 1 is a post element 10 which comprises a generally open shaped channel section where three sides 11, 12.1 and 12.2 of the channel section 10 are fully closed and the front side 13 which has a reduced width panel receiving opening 14 made up from two side flanges 17 and 18 extending towards each other from the sides 12.1 and 12.2. The two flanges 17 and 18 end in inwardly turned or directed flanges 15 and 16. [056] The post element 13 either can be sheet metal and roll formed to a required length or of indefinite length and then cut to the required length. In manufacturing the post element of Figure 1, this element can be manufactured from roll forming, for example, from a Colorbond (registered trade mark) or other power coated material or could be extruded from a die in aluminium. [057] The flanges 15 and 16 are generally at approximately 45 degrees to the side portions 17 and 18. [058] The opening 14 is preferably of a width W when the element is manufactured. The width W is substantially less than the width of a panel which is to be inserted therein. More will be said about this later.

6 [059] Illustrated in Figure 2 is a mid post or 180 degree post which has two panel openings 14 which are in line with each other so that when two panels are placed in these respective openings the panels will form approximately a straight line with the post of Figure 2 in the middle thereof. To manufacture the post of Figure 2 two elements of Figure 1 are placed back to back that is so that their backs 11 are arranged so as to be facing each other. These are then secured either by one or more of the following methods: adhering or bonding by chemical adhesive between the two planar surfaces 11; one or more screws or self-tapping screws or nuts and bolts applied in the direction of arrows 19, 20, 21 or 22 or other appropriate means such as production of a series of holes through the centre of the back 11 so that the holes will sit back to back and these can then be tied by wire ties or purpose built ties. Other joining means like a series of tongues and apertures can also be provided but this may mean greater inventory as one post section will have to have apertures to receive tongues on a different shaped post. While this can be done, it is a commercially better prospect to have only a single post which is joinable to a like post, and not have two different post elements. [060] An advantage of the above system is that suppliers of fencing materials need only keep one post element of standard length in their inventory and the customers will purchase and put together posts according to their needs. This makes the fencing system readily able to be introduced by retail outlets with a minimum of inventory and space required for the system. [061] Illustrated in Figures 3 to 6 is a bracket system for use with the post of figures 1 and 2. Before assembling the post into a post hole or driving same into the ground or encasing it in concrete in a post hole, an L-bracket 90 such as that illustrated in Figure 5 which has a panel support portion 91 which also doubles as a post engagement portion, and a bridging section 93 at right angles to the portion 91. The bridging section 93 has a series of four holes 94. The bracket 90 is placed in the opening 14 of a post such as that of Figure 1 or Figure 2 so that the opening 14 of width W is expanded to the width dimension of the portion 91. The action of positioning the bracket 90 is to align the width w1 so that it is generally vertical or angled so that it will readily move into the opening 14, and then once in to rotate the portion 91 so that it engages the ends of the flanges 15 and 16 with the rotation action moving the flanges 15 and 16 to the desired width to receive a panel. The portion 91 is of approximately the same width as the panels 40. Once the bracket 90 has been put into the opening 14 the bracket is then rotated so that the section 91 is at right angles to the longitudinal direction of the post, as is best illustrated in Figure 6.

7 [062] An alternative method of assembly of the bracket 90 with the post is to simply orient the portion 91 so that it is perpendicular to the post's longitudinal axis and then simply push the portion 91 so that it engages the angled flanges 15 and 16 on side 13. As the flanges 15 and 16 are at 45 degrees to the flanges 17 and 18, the corners of the bracket 90 which first engages the flanges 15 and 16, will effectively be engaging an inclined plane, and thus by a sufficient force being applied by the assembler, the flanges 15 and 16 will open to the desired width by the action of pushing the portion 91 into the opening 14. To this end the free corners of the portion 91 may be radiused or angled so that the interaction with the inclined planes of the exterior faces of flanges 15 and 16 will result in less friction and thus a reduced force required to insert the portion 91 into opening 14. [063] As can be best seen from figure 6, the portion 91 extends inwardly of the post and sits generally horizontally is the post is vertical. This means that the portion 91 provide support surface which is the full width of the opening 14 and the equal to the width of the panels 40 which will go into the opening 14. In this way the portion 91 acts as both a panel support and post engagement portion. [064] Once in the desired position, the screw holes 94 are used by the installer to secure the bracket via self-tapping and or self-drilling screws to the planar post flanges 17 and 18 on the side 13 of a post element. This is done at approximately ground level or fractionally below ground level where the bracket 90 can be just below the surface of concrete. [065] Illustrated in Figures 7 and 8 is the posts of Figures 1 and 2 shown with panels 40 having been inserted in the gap or panel receiving portion 14. The panel 40 is preferably made from a 4.5 mm fibre cement panel or magnesium board 41 on one side and a similar panel 42 on the other. The panels 42 and 41 are adhered to a polystyrene or EPS polystyrene foam core 43 which can be shaped at its upper or lower edges 44 so as to interlock with a panel from above which would have a similarly mating formation. [066] To assemble a fence or wall with the above post and panel, one post as illustrated in Figure 13, namely, an assembled post 50, made up of two post sections 10 back to back, is placed in a dug post hole 51 to a specified depth of approximately 600 mms. The post 50 is supported in any known manner and concrete poured in the post hole 51 to secure the post 50 in an upright condition. [067] If desired only end posts need be placed in concrete with mid posts being simply driven into the ground. The most robust construction is achieved if each post is placed in similar post holes 51 and anchored therein by means of cement or other grouting type materials. This 8 provides the post with a panel receiving opening 14 of approximately the correct width at the base of the post and allows a first or lower panel 100 as illustrated in Figures 11 and 12 to be installed between adjacent posts. Then the second layer of panels 200 can be inserted and made to inter-engage with the panels below if required or just to sit separately thereof and adjacent thereto. In the fence of Figure 12, a third layer of panel elements 300 are installed to bring the fence up to the desired height. [068] The panel element is preferably sitting in the post with only a light frictional contact with the free edges of the inwardly extending sides 15 and 16 exerting relatively little pressure thereon. This reasonably snug fit still provides a fence of high strength and quality and yet is relatively quick and easy to assemble without the need of complex tools and specialist trades. [069] Preferably the bracket 90 is manufactured from 3 mm plate steel which is stamped and pressed (then galvanised) to the appropriate form. [070] To assemble a fence or wall, so that the posts of figure 11 and 12 are at the correct distance apart, a decorative or strengthening member 70 is provided as is illustrated in figures 15 to 19. The member 70 is an open channel having three sides, a front 70.1, two right angle side portions 70.2 and 70.3 which respectively have angled flanges 71 and 72 extending therefrom and at an angle of approx 45 degrees thereto. The member 70 if used with a post 10 can be inserted in the manner of figure 17 where the front 70.1 will close off the opening 14 to produce a generally closed section post element. In this arrangement the member 70 is used as a decorative element which eliminates the exposed free edges of the flanges 15 and 16. If the member 70 were to be inserted into the post 10 around 180 degrees from the orientation illustrated in figure 17, then the opening 14 remains open and the assembled post element is now a double walled post element on three sides, thereby producing a reinforced post element which may be needed in high wind area applications. [071] Depending upon corner post configurations which may be required, such as a corner post of the construction of figure 21, one of the openings 14 is redundant and can be closed off. Or if a post such as that illustrated in figure 20 were to be needed a closed section can be readily assembled by the use of the member 70. [072] The member 70 is produced in the standard length which is equivalent to the length of the post and which is also marginally longer than the length of the panels 40. As the member 70 is in all likelihood going to be required on most fence or wall assemblies, the assembler can use the member 70 as ruler or spacer whereby once the posts have their 9 brackets 90 installed as illustrated in figure 15, the member 70 is positioned inside the opening 14 as the distance from the side 70.1 to the free edges of flanges 71 and 72 is less than the width W of the openings 14. This means it enters the openings 14 without having to force the openings 14 with a bracket 90 in place. With a post located at either end of the member 70, as illustrated in figure 19, the inside faces of the backs 11 of posts 10 are now spaced at the right distance apart, as in Figure 19, to receive a panel 100 or 40 therein. This member also provides a horizontal surface to place a spirit level on to obtain correct vertical alignment of consecutive posts. [073] While the best joining method of the above described post elements 10 is by joining the backs 11 thereof, other jointing could occur such as joining in back 11 to side 12 as in figure 10. If a stronger post corner assembly is required a square hollow section can be used with the posts 10 placed back to back with two side of the 90mm x 90mm square hollow section as illustrated in figure 9. [074] In the corner post embodiment of figure 21, three half post 10 are used whereby two posts 10 are back to back while the third has its back to aligned sides of the other two. The contacting surfaces can all receive self tapping screws to effect the securing of the assembly posts together. [075] Illustrated in Figures 27 to 29 is an in-fill member 80 and post or post element 110 and an assembly of these of another embodiment similar to that of Figures 1 and 2, and like ports have been like numbered. [076] The in-fill member 80 has, in the cross-section or plan view of Figure 27, a planar portion 82, angled sides 84, which are respectively at approximately 1350 (or 450 as the supplementary angle) to the planar portion 82. The sides 84 form the first half of, or a lead in to, a hook portion 86, which is formed from a side 87, a bend 88, and further side 90 which is generally parallel to the respective sides 17 and 18. The planar portion 82, as discussed below, closes off the opening in the post or post element 110 allowing the assembly to appear whole. [077] The post or post element 110 of figure 28, like previous embodiments includes the sides 16 and 15, which are respectively approximately 1350 to the sides 18 and 17 (or 450 being the supplementary angle to the direction of extension of sides 18 and 17). [078] The sides 15 and 16 extend into a round end portion 16.2 and 15.2, and from this extends another inwardly directed side 15.1 and 16.1 with respect to the element 110, and a sideways directed sides 16.3 and 15.3 which are respectively generally parallel to the sides 18 and 17.

10 [079] The sides 15.2 and 16.2 are inwardly directed with respect to the post or post element 110, but the side 16.2 also extends towards the side 12.1 from which side 17 depends, while side 15.2 is also extending towards side 12.2 from which side 18 depends. [080] Further, sides 15.1 and 16.1 while also being inwardly directed with respect to the post or post element 110, are such that the side 16.1 extends towards side 12.2, while side 15.1 extends towards side 12.1. [081] This arrangement forms a smooth entry passage for a beam or horizontal 90 and a panel 40, as well as providing an element of bias as provided by the previous embodiments. [082] Further, the hook system formed by sides 16, 16.1, curved portion 16.2 and side 16.3, and 15, 15.1, curved portion 15.2 and side 15.3, provides a means for the hooks 86 of the in-fill member 80 to engage, as is illustrated in Figure 29. This results in a more efficient in-fill i.e. less metal by comparison to in-fill 70 of Figure 20, and further the in-fill 80 has the other result of assisting to maintain the shape of post or post element 110 of Figure 28 and 29, by preventing sides 18 and 17 moving away from each other, except in the case of excessive forces. Like the previously described embodiments, the in-fill 80 and post or post element 110 can be readily manufactured by roll forming or any other appropriate manufacturing method such as extrusion. [083] The affixing of one post element to the other can be performed at one or more of the following locations: near the top of the arranged elements; near the top and bottom; one location between top and bottom; multiple locations between top and bottom. [084] The preferred post size is one where the back is approx 90 mm in width while the sides are approx 45 mm in width. IF a post with sides of smaller dimension were selected, say for example 38 mm then such a post would, in a side on orientation be able to be inserted into the openings 14, as the width of the panels is approx 40mm. With such a 38 mm post, as all post are of the same length, which is the same length as the member 70, for example 2.4 metres, then instead of using a member 70 to be a spacer in the post layout as illustrated in figure 19, a 38mm sided post can be used in its stead. This means that the fencing system with these features can be purchased with either member 70 or a 38 mm sided post which will be a readily available spacer for use by the assembler. [085] Where ever it is used, the word "comprising" is to be understood in its "open" sense, that is, in the sense of "including", and thus not limited to its "closed" sense, that is the sense of "consisting only of". A corresponding meaning is to be attributed to the corresponding words "comprise", "comprised" and "comprises" where they appear.

11 [086] It will be understood that the invention disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text. All of these different combinations constitute various alternative aspects of the invention. [087] While particular embodiments of this invention have been described, it will be evident to those skilled in the art that the present invention may be embodied in other specific forms without departing from the essential characteristics thereof. The present embodiments and examples are therefore to be considered in all respects as illustrative and not restrictive, and all modifications which would be obvious to those skilled in the art are therefore intended to be embraced therein.

Claims (25)

1. A post or post element having at least three sides, a first side being a joining side to join to a like sided element to create a post, a second side and a third side forming a panel receiving opening.

2. A post element as claimed in claim 1, wherein said post element is manufactured by rolling, pressing or extruding.

3. A post element as claimed in claims 1 or 2, wherein said post element is formed whereby panel receiving opening is narrower than the panel to be inserted therein.

4. A post element as claimed in any one of the preceding claims wherein said post element is manufactured from a powder coated or zinc coated steel sheet material or aluminium.

5. A post element as claimed in any one of the preceding claims wherein said panel receiving opening includes an inwardly extending side on either side thereof.

6. A post element as claimed in claim 5, wherein said inwardly extending side lies at an angle to said second and or said third side, said inwardly extending side having a further inwardly extending side extending therefrom.

7. A post for a fencing system being made from a post or post element as claimed in any one of the preceding claims wherein two post elements as claimed in any one of the preceding claims are arranged so that their joining faces lie adjacent to each other.

8. A fence post as claimed in claim 7 wherein the joining faces are secured together by means of one or more of the following: adhesive, a screw, screws, a bolt, bolts, cold working, apertures in said joining sides being tied, or other appropriate means.

9. A post as claimed in any one of claims 7 or 8 wherein the two elements are arranged so that the panel receiving openings lie generally on a straight line.

10. A fence post as claimed in any one of claims 7 or 8, wherein the two panel openings are arranged so as to lie at 90 degrees in the post. 13

11. A method of assembling a post, said method including the step of arranging a post element as claimed in any one of claims 1 to 6 so that said first sides are adjacent each other, or a first side of one element is adjacent a second side of another element; and affixing said adjacent sides together.

12. A method as claimed in claim 11 wherein said affixing is done at one or more of the following locations near the top; near the top and bottom; one location between top and bottom; multiple locations between top and bottom.

13. A method of constructing a fence utilising a post element or post as claimed in any one of the preceding claims wherein a panel supporting bracket which includes a portion having a width to provide sufficient clearance for a panel to be inserted in said panel receiving opening.

14. A method as claimed in claim 13, wherein said bracket is inserted into said panel receiving opening and rotated to expand said panel receiving opening to a width of a panel to be received therein; or said bracket is pushed into said panel receiving opening engaging angled flanges which act as inclined planes so that said opening is widened as said bracket is pushed therein.

15. A method as claimed in claim 14, wherein said method also includes the step of securing said bracket to either side of said panel receiving opening by means of an axial pin joiner such as a rivet or a self-drilling and self-tapping screw.

16. A method as claimed in claims 14 or 15, wherein method includes constructing said panel from two outer layers of fibre cement panel or magnesium board and a core of a polymeric material such as EPS, polystyrene or other appropriate material.

17. A method of assembling a fence or wall including the steps of: (a) joining two post elements, as claimed in any one of the preceding claims together to form a 180 or 90 degree post element for the receiving of panels at 180 or 90 degrees with respect to each other: (b) positioning a bracket in a panel receiving opening to expand said panel receiving opening to an appropriate width; (c) securing said bracket to said element; (b) inserting a panel in said panel receiving opening between two post elements. 14

18. A method as claimed in any one of the preceding claims wherein a post cap is placed upon said post.

19. A method as claimed in any one of the preceding claims, wherein an end cap is placed upon the top layer of said panel.

20. A post element as claimed in any one of the preceding claims wherein the second side is a planar side.

21. A fence system including post elements and panel elements wherein the post elements are of a predetermined length which is marginally larger than the length of the panels to be assembled with said post, said posts including panel receiving openings in one side of said post elements.

22. A fence system as claimed in claim 21, wherein said system includes a spacing element of the same length as said posts and which is of a side dimension which is smaller than said panel receiving openings, so that said post can be inserted into said panel receiving openings whereby a post element can be used as a spacer for an assembler to space the posts to receive a panel during assembly.

23. A fence system as claimed 22, wherein said spacing element is one of: a post; a decorative member; a strengthening member.

24. An in-fill member for a post or post element, wherein said in-fill member includes in cross-section a generally planar body and two inwardly directed channels at the sides of said body so as to receive said further inwardly extending sides of said post or post element of claim 6.

25. A post or post element as claimed in any one of the preceding claims, assembled with an in-fill member as claimed in claim 24.